Miller Electric Big Blue 300 P Users Manual O4433k_mil(eco3724)

300 P to the manual a157720d-cb1b-48be-9a81-dbddeb03f73b

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Big Blue 300 P

OM-4433 218 314K

2006−11

Processes

Description

Air Carbon Arc (CAC-A)

Cutting and Gouging

Stick (SMAW) Welding

Engine Driven Welding Generator

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

®

Visit our website at

www.MillerWelds.com

File: Engine Drive

Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor to receive the latest full

line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can get

the job done and get it done right. We know you don’t have time to do

it any other way.

That’s why when Niels Miller first started building arc welders in 1929,

he made sure his products offered long-lasting value and superior

quality. Like you, his customers couldn’t afford anything less. Miller

products had to be more than the best they could be. They had to be the

best you could buy.

Today, the people that build and sell Miller products continue the

tradition. They’re just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

there’s a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001:2000 Quality

System Standard.

Working as hard as you do

− every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Mil_Thank 4/05

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Engine Hazards 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Compressed Air Hazards 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. California Proposition 65 Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-8. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers existant en relation avec le moteur 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Dangers liés à l’air comprimé 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7 . . . . . .

2-6. Proposition californienne 65 Avertissements 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Information EMF 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Warning Label Definitions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Manufacturer’s Rating Label 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Symbols And Definitions 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Weld, Power, And Engine Specifications 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Dimensions, Weights, And Operating Angles 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Volt-Ampere Curves 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Fuel Consumption 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Duty Cycle And Overheating 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. AC Generator Power Curve 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Mounting Welding Generator 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Installing Exhaust Pipe 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Activating The Dry Charge Battery (If Applicable) 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Connecting The Battery 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Engine Prestart Checks 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Connecting To Weld Output Terminals 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Selecting Weld Cable Sizes* 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Connecting To Remote 14 Receptacle RC14 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING WELDING GENERATOR 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Front Panel Controls (See Section 6-2) 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Description Of Front Panel Controls (See Section 6-1) 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Process/Contactor Switch 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Lift-Arc Start Procedure 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Remote Voltage/Amperage Control 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − OPERATING AUXILIARY EQUIPMENT 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Generator Power Receptacles 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − MAINTENANCE & TROUBLESHOOTING 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Routine Maintenance 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Maintenance Label 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Servicing Air Cleaner 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

8-5. Servicing Engine Cooling System 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Adjusting Engine Speed On Standard Models 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Adjusting Engine Speed On Models With Automatic Idle (Optional) 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8. Servicing Fuel And Lubrication Systems 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9. Overload Protection 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10. Checking Generator Brushes 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-11. Voltmeter/Ammeter Help Displays 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-12. Troubleshooting 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − ELECTRICAL DIAGRAMS 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − RUN-IN PROCEDURE 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Wetstacking 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Run-In Procedure Using Load Bank 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Run-In Procedure Using Resistance Grid 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − GENERATOR POWER GUIDELINES 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − PARTS LIST 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-4433 Page 1

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom _nd_3/05

Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Marks a special safety message.

Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see the

symbol, watch out, and follow the related instructions to avoid the

hazard. The safety information given below is only a summary of

the more complete safety information found in the Safety Stan-

dards listed in Section 1-7. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and re-

pair this unit.

During operation, keep everybody, especially children, away.

Touching live electrical parts can cause fatal shocks or

severe burns. The electrode and work circuit is electrically

live whenever the output is on. The input power circuit and

machine internal circuits are also live when power is on. In semiautomatic or

automatic wire welding, the wire, wire reel, drive roll housing, and all metal

parts touching the welding wire are electrically live. Incorrectly installed or

improperly grounded equipment is a hazard.

ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating mats or covers

big enough to prevent any physical contact with the work or ground.

Do not use AC output in damp areas, if movement is confined, or if there is a

danger of falling.

Use AC output ONLY if required for the welding process.

If AC output is required, use remote output control if present on unit.

Additional safety precautions are required when any of the following electri-

cally hazardous conditions are present: in damp locations or while wearing

wet clothing; on metal structures such as floors, gratings, or scaffolds;

when in cramped positions such as sitting, kneeling, or lying; or when there

is a high risk of unavoidable or accidental contact with the workpiece or

ground. For these conditions, use the following equipment in order present-

ed: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most

situations, use of a DC, constant voltage wire welder is recommended.

And, do not work alone!

Disconnect input power or stop engine before installing or servicing this

equipment. Lockout/tagout input power according to OSHA 29 CFR

1910.147 (see Safety Standards).

Properly install and ground this equipment according to its Owner’s Manual

and national, state, and local codes.

Always verify the supply ground — check and be sure that input power cord

ground wire is properly connected to ground terminal in disconnect box or

that cord plug is connected to a properly grounded receptacle outlet.

When making input connections, attach proper grounding conductor first −

double-check connections.

Frequently inspect input power cord for damage or bare wiring — replace

cord immediately if damaged — bare wiring can kill.

Turn off all equipment when not in use.

Do not use worn, damaged, undersized, or poorly spliced cables.

Do not drape cables over your body.

If earth grounding of the workpiece is required, ground it directly with a sep-

arate cable.

Do not touch electrode if you are in contact with the work, ground, or anoth-

er electrode from a different machine.

Use only well-maintained equipment. Repair or replace damaged parts at

once. Maintain unit according to manual.

Do not touch electrode holders connected to two welding machines at

the same time since double open-circuit voltage will be present.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

Clamp work cable with good metal-to-metal contact to workpiece or work-

table as near the weld as practical.

Insulate work clamp when not connected to workpiece to prevent contact

with any metal object.

Do not connect more than one electrode or work cable to any single weld

output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop-

ping engine.

Stop engine on inverter and discharge input capacitors according to

instructions in Maintenance Section before touching any parts.

Welding produces fumes and gases. Breathing these fumes

and gases can be hazardous to your health.

FUMES AND GASES can be hazardous.

Keep your head out of the fumes. Do not breathe the fumes.

If inside, ventilate the area and/or use local forced ventilation at the arc to

remove welding fumes and gases.

If ventilation is poor, wear an approved air-supplied respirator.

Read and understand the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings, cleaners,

and degreasers.

Work in a confined space only if it is well ventilated, or while wearing an air-

supplied respirator. Always have a trained watchperson nearby. Welding

fumes and gases can displace air and lower the oxygen level causing injury

or death. Be sure the breathing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying operations.

The heat and rays of the arc can react with vapors to form highly toxic and

irritating gases.

Do not weld on coated metals, such as galvanized, lead, or cadmium plated

steel, unless the coating is removed from the weld area, the area is well

ventilated, and while wearing an air-supplied respirator. The coatings and

any metals containing these elements can give off toxic fumes if welded.

BUILDUP OF GAS can injure or kill.

Shut off shielding gas supply when not in use.

Always ventilate confined spaces or use approved

air-supplied respirator.

Arc rays from the welding process produce intense visible

and invisible (ultraviolet and infrared) rays that can burn eyes

and skin. Sparks fly off from the weld.

ARC RAYS can burn eyes and skin.

Wear an approved welding helmet fitted with a proper shade of filter lenses

to protect your face and eyes from arc rays and sparks when welding or

watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

Wear approved safety glasses with side shields under your helmet.

Use protective screens or barriers to protect others from flash, glare, and

sparks; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant material

(leather, heavy cotton, or wool) and foot protection.

OM-4433 Page 2

Welding on closed containers, such as tanks, drums, or

pipes, can cause them to blow up. Sparks can fly off from the

welding arc. The flying sparks, hot workpiece, and hot

equipment can cause fires and burns. Accidental contact of electrode to metal

objects can cause sparks, explosion, overheating, or fire. Check and be sure

the area is safe before doing any welding.

WELDING can cause fire or explosion.

Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not

possible, tightly cover them with approved covers.

Do not weld where flying sparks can strike flammable material.

Protect yourself and others from flying sparks and hot metal.

Be alert that welding sparks and hot materials from welding can easily go

through small cracks and openings to adjacent areas.

Watch for fire, and keep a fire extinguisher nearby.

Be aware that welding on a ceiling, floor, bulkhead, or partition can cause

fire on the hidden side.

Do not weld on closed containers such as tanks, drums, or pipes, unless

they are properly prepared according to AWS F4.1 (see Safety Standards).

Connect work cable to the work as close to the welding area as practical to

prevent welding current from traveling long, possibly unknown paths and

causing electric shock, sparks, and fire hazards.

Do not use welder to thaw frozen pipes.

Remove stick electrode from holder or cut off welding wire at contact tip

when not in use.

Wear oil-free protective garments such as leather gloves, heavy shirt, cuf-

fless trousers, high shoes, and a cap.

Remove any combustibles, such as a butane lighter or matches, from your

person before doing any welding.

Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot

work and have a fire watcher and extinguisher nearby.

FLYING METAL can injure eyes.

Welding, chipping, wire brushing, and grinding cause

sparks and flying metal. As welds cool, they can

throw off slag.

Wear approved safety glasses with side shields even

under your welding helmet.

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed.

Allow cooling period before working on equipment.

To handle hot parts, use proper tools and/or wear

heavy, insulated welding gloves and clothing to pre-

vent burns.

NOISE can damage hearing.

Noise from some processes or equipment can damage

hearing.

Wear approved ear protection if noise level is high.

MAGNETIC FIELDS can affect pacemakers.

Pacemaker wearers keep away.

Wearers should consult their doctor before going

near arc welding, gouging, or spot welding opera-

tions.

Shielding gas cylinders contain gas under high pressure. If

damaged, a cylinder can explode. Since gas cylinders are

normally part of the welding process, be sure to treat them

carefully.

CYLINDERS can explode if damaged.

Protect compressed gas cylinders from excessive heat, mechanical

shocks, physical damage, slag, open flames, sparks, and arcs.

Install cylinders in an upright position by securing to a stationary support or

cylinder rack to prevent falling or tipping.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder — explosion will result.

Use only correct shielding gas cylinders, regulators, hoses, and fittings de-

signed for the specific application; maintain them and associated parts in

good condition.

Turn face away from valve outlet when opening cylinder valve.

Keep protective cap in place over valve except when cylinder is in use or

connected for use.

Use the right equipment, correct procedures, and sufficient number of per-

sons to llift and move cylinders.

Read and follow instructions on compressed gas cylinders, associated

equipment, and Compressed Gas Association (CGA) publication P-1 listed

in Safety Standards.

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

Always wear a face shield, rubber gloves, and protec-

tive clothing when working on a battery.

Stop engine before disconnecting or connecting bat-

tery cables or servicing battery.

Do not allow tools to cause sparks when working on a battery.

Do not use welder to charge batteries or jump start vehicles.

Observe correct polarity (+ and −) on batteries.

Disconnect negative (−) cable first and connect it last.

FUEL can cause fire or explosion.

Stop engine and let it cool off before checking or add-

ing fuel.

Do not add fuel while smoking or if unit is near any

sparks or open flames.

Do not overfill tank — allow room for fuel to expand.

Do not spill fuel. If fuel is spilled, clean up before starting engine.

Dispose of rags in a fireproof container.

Always keep nozzle in contact with tank when fueling.

MOVING PARTS can cause injury.

Keep away from fans, belts, and rotors.

Keep all doors, panels, covers, and guards closed

and securely in place.

Stop engine before installing or connecting unit.

Have only qualified people remove doors, panels, covers, or guards for

maintenance and troubleshooting as necessary.

To prevent accidental starting during servicing, disconnect negative (−)

battery cable from battery.

Keep hands, hair, loose clothing, and tools away from moving parts.

Reinstall doors, panels, covers, or guards when servicing is finished and

before starting engine.

Before working on generator, remove spark plugs or injectors to keep

engine from kicking back or starting.

Block flywheel so that it will not turn while working on generator compo-

nents.

HOT PARTS can cause severe burns.

Do not touch hot engine parts.

Allow cooling period before maintaining.

Wear protective gloves and clothing when working on

a hot engine.

OM-4433 Page 3

STEAM AND HOT COOLANT can burn.

If possible, check coolant level when engine is cold to

avoid scalding.

Always check coolant level at overflow tank, if pres-

ent on unit, instead of radiator (unless told otherwise

in maintenance section or engine manual).

If the engine is warm, checking is needed, and there is no overflow tank,

follow the next two statements.

Wear safety glasses and gloves and put a rag over radiator cap.

Turn cap slightly and let pressure escape slowly before completely re-

moving cap.

ENGINE EXHAUST GASES can kill.

Use equipment outside in open, well-ventilated ar-

eas.

If used in a closed area, vent engine exhaust outside

and away from any building air intakes.

BATTERY ACID can BURN SKIN and EYES.

Do not tip battery.

Replace damaged battery.

Flush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

Do not locate unit on, over, or near combustible

surfaces or flammables.

Keep exhaust and exhaust pipes way from flam-

mables.

EXHAUST SPARKS can cause fire.

Do not let engine exhaust sparks cause fire.

Use approved engine exhaust spark arrestor in re-

quired areas — see applicable codes.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can

cause serious injury or death.

Do not use compressed air for breathing.

Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

Wear approved safety goggles.

Do not direct air stream toward self or others.

TRAPPED AIR PRESSURE AND WHIPPING

HOSES can cause injury.

Release air pressure from tools and system before

servicing, adding or changing attachments, or open-

ing compressor oil drain or oil fill cap.

HOT METAL from air arc cutting and

gouging can cause fire or explosion.

Do not cut or gouge near flammables.

Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury.

Do not touch hot compressor or air system parts.

Let system cool down before touching or servicing.

READ INSTRUCTIONS.

Read Owner’s Manual before using or servicing unit.

Stop engine and release air pressure before

servicing.

Use only genuine Miller/Hobart replacement parts.

1-5. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.

Use lifting eye to lift unit and properly installed acces-

sories only. Do not exceed maximum lift eye weight

rating (see Specifications).

Lift and support unit only with proper equipment and

correct procedures.

If using lift forks to move unit, be sure forks are long

enough to extend beyond opposite side of unit.

OVERHEATING can damage motors.

Turn off or unplug equipment before starting or stop-

ping engine.

Do not let low voltage and frequency caused by low

engine speed damage electric motors.

Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where

applicable.

FLYING SPARKS can cause injury.

Wear a face shield to protect eyes and face.

Shape tungsten electrode only on grinder with proper

guards in a safe location wearing proper face, hand,

and body protection.

Sparks can cause fires — keep flammables away.

OVERUSE can cause OVERHEATING.

Allow cooling period; follow rated duty cycle.

Reduce current or reduce duty cycle before starting

to weld again.

Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handling

boards or parts.

Use proper static-proof bags and boxes to store,

move, or ship PC boards.

TILTING OF TRAILER can cause injury.

Use tongue jack or blocks to support weight.

Properly install welding generator onto trailer accord-

ing to instructions supplied with trailer.

OM-4433 Page 4

READ INSTRUCTIONS.

Use only genuine MILLER/Hobart replacement

parts.

Perform engine and air compressor (if applicable)

maintenance and service according to this manual

and the engine/air compressor (if applicable) manu-

als.

H.F. RADIATION can cause interference.

High-frequency (H.F.) can interfere with radio naviga-

tion, safety services, computers, and communica-

tions equipment.

Have only qualified persons familiar with electronic

equipment perform this installation.

The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the installation.

If notified by the FCC about interference, stop using the equipment at

once.

Have the installation regularly checked and maintained.

Keep high-frequency source doors and panels tightly shut, keep spark

gaps at correct setting, and use grounding and shielding to minimize the

possibility of interference.

ARC WELDING can cause interference.

Electromagnetic energy can interfere with sensitive

electronic equipment such as microprocessors,

computers, and computer-driven equipment such as

robots.

Be sure all equipment in the welding area is electro-

magnetically compatible.

To reduce possible interference, keep weld cables as short as possible,

close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive electronic

equipment.

Be sure this welding machine is installed and grounded according to this

manual.

If interference still occurs, the user must take extra measures such as

moving the welding machine, using shielded cables, using line filters, or

shielding the work area.

1-6. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California Health &

Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductive harm. Wash hands after handling.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive

harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

from Global Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from Global Engineering Documents (phone:

1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA

02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www.

sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1735 Jefferson Davis Highway,

Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:

www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale Bou-

levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or

in Toronto 416-747-4044, website: www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11

West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,

website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:

617-770-3000, website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there

are 10 Regional Offices—phone for Region 5, Chicago, is

312-353-2220, website: www.osha.gov).

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from

operator as practical.

5. Connect work clamp to workpiece as close to the weld as

possible.

About Pacemakers:

Pacemaker wearers consult your doctor before welding or going near

welding operations. If cleared by your doctor, then following the above

procedures is recommended.

OM-4433 Page 5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_fre 3/05

Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.

2-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure

présente des risques de danger ! Ceux-ci sont identifiés

par des symboles adjacents aux directives.

Identifie un message de sécurité particulier.

Signifie NOTA ; n’est pas relatif à la sécurité.

Ce groupe de symboles signi-

fie Mise en garde ! Soyez vigi-

lant ! Il y a des risques de dan-

ger reliés aux CHOCS ÉLEC-

TRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Repor-

tez-vous aux symboles et aux directives ci-dessous afin de connaître les mesu-

res à prendre pour éviter tout danger.

2-2. Dangers relatifs au soudage à l’arc

Les symboles présentés ci-après sont utilisés tout au long du présent

manuel pour attirer votre attention et identifier les risques de danger.

Lorsque vous voyez un symbole, soyez vigilant et suivez les directives

mentionnées afin d’éviter tout danger. Les consignes de sécurité pré-

sentées ci-après ne font que résumer l’information contenue dans les

normes de sécurité énumérées à la section 2-7 . Veuillez lire et respecter

toutes ces normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne doivent être

confiés qu’à des personnes qualifiées.

Au cours de l’utilisation, tenir toute personne à l’écart et plus particu-

lièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut provo-

quer une électrocution ou des blessures graves. L’électrode

et le circuit de soudage sont sous tension dès que l’appareil

est sur ON. Le circuit d’entrée et les circuits internes de

l’appareil sont également sous tension à ce moment-là. En

soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des

galets d’entraînement et les pièces métalliques en contact avec le fil de soudage

sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un

danger.

Ne jamais toucher les pièces électriques sous tension.

Porter des gants et des vêtements de protection secs ne comportant pas de

trous.

S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens iso-

lants suffisamment grands pour empêcher le contact physique éventuel avec

la pièce ou la terre.

Ne pas se servir de source électrique à courant électrique dans les zones hu-

mides, dans les endroits confinés ou là où on risque de tomber.

Se servir d’une source électrique à courant électrique UNIQUEMENT si le

procédé de soudage le demande.

Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire,

se servir de la fonction de télécommande si l’appareil en est équipé.

Des précautions de sécurité supplémentaires sont requises dans des envi-

ronnements à risque comme: les endroits humides ou lorsque l’on porte des

vêtements mouillés; sur des structures métalliques au sol, grillages et écha-

faudages; dans des positions assises, à genoux et allongées; ou quand il y a

un risque important de contact accidentel avec la pièce ou le sol. Dans ces cas

utiliser les appareils suivants dans l’ordre de préférence: 1) un poste à souder

DC semi−automatique de type CV (MIG/MAG), 2) un poste à souder manuel

(électrode enrobée) DC, 3) un poste à souder manuel AC avec tension à vide

réduite. Dans la plupart des cas, un poste courant continu de type CV est re-

commandé. Et, ne pas travailler seul!

Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à

la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la

norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

Installer et mettre à la terre correctement cet appareil conformément à son

manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le

fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du

sectionneur ou que la fiche du cordon est raccordée à une prise correctement

mise à la terre.

En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise

à la terre approprié et contre-vérifier les connexions.

Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endom-

magé ou dénudé − remplacer le cordon immédiatement s’il est endommagé −

un câble dénudé peut provoquer une électrocution.

Mettre l’appareil hors tension quand on ne l’utilise pas.

Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou

mal épissés.

Ne pas enrouler les câbles autour du corps.

Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour.

Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou

une électrode provenant d’une autre machine.

Ne pas toucher des porte électrodes connectés à deux machines en même

temps à cause de la présence d’une tension à vide doublée.

N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ les

pièces endommagées. Entretenir l’appareil conformément à ce manuel.

Porter un harnais de sécurité quand on travaille en hauteur.

Maintenir solidement en place tous les panneaux et capots.

Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec la

pièce à souder ou la table de travail, le plus près possible de la soudure.

Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec

tout objet métallique.

Une tension DC importante subsiste à l’intérieur des

onduleurs après avoir coupé l’alimentation.

Couper l’alimentation du poste et décharger les condensateurs d’entrée com-

me indiqué dans la Section Maintenance avant de toucher des composants.

LES FUMÉES ET LES GAZ peuvent être

dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation

peut être dangereux pour votre santé.

Eloigner votre tête des fumées. Ne pas respirer les fumées.

À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de

l’arc pour l’évacuation des fumées et des gaz de soudage.

Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.

Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et les

instructions du fabricant concernant les métaux, les consommables, les revê-

tements, les nettoyants et les dégraisseurs.

Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant

un respirateur à alimentation d’air. Demander toujours à un surveillant dûment

formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent dé-

placer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des

accidents mortels. S’assurer que l’air de respiration ne présente aucun dan-

ger.

Ne pas souder dans des endroits situés à proximité d’opérations de dégrais-

sage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc

peuvent réagir en présence de vapeurs et former des gaz hautement toxiques

et irritants.

Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé,

plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé

dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respi-

rateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces

éléments peuvent dégager des fumées toxiques en cas de soudage.

LES ACCUMULATIONS DE GAZ ris-

quent de provoquer des blessures ou

même la mort.

Fermer l’alimentation du gaz protecteur en cas de non utili-

sation.

Veiller toujours à bien aérer les espaces confinés ou se servir d’un respira-

teur d’adduction d’air homologué.

LES RAYONS DE L’ARC peuvent pro-

voquer des brûlures dans les yeux et

sur la peau.

Le rayonnement de l’arc du procédé de soudage génère des

rayons visibles et invisibles intenses (ultraviolets et infrarou-

ges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des

étincelles sont projetées pendant le soudage.

Porter un casque de soudage approuvé muni de verres filtrants approprié

pour protéger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1

énuméré dans les normes de sécurité).

Porter des lunettes de sécurité avec écrans latéraux même sous votre cas-

que.

Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les au-

tres contre les rayonnements les éblouissements et les étincelles ; prévenir

toute personne sur les lieux de ne pas regarder l’arc.

Porter des vêtements confectionnés avec des matières résistantes et ignifu-

ges (cuir, coton lourd ou laine) et des bottes de protection.

OM-4433 Page 6

Le soudage effectué sur des conteneurs fermés tels que des

réservoirs, tambours ou des conduites peut provoquer leur

éclatement. Des étincelles peuvent être projetées de l’arc de

soudure. La projection d’étincelles, des pièces chaudes et des équipements

chauds peut provoquer des incendies et des brûlures. Le contact accidentel de

l’électrode avec des objets métalliques peut provoquer des étincelles, une

explosion, un surchauffement ou un incendie. Avant de commencer le soudage,

vérifier et s’assurer que l’endroit ne présente pas de danger.

LE SOUDAGE peut provoquer un in-

cendie ou une explosion.

Déplacer toutes les substances inflammables à une distance de 10,7 m de

l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des

protections homologués.

Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des

substances inflammables.

Se protéger et d’autres personnes de la projection d’étincelles et de métal

chaud.

Des étincelles et des matériaux chauds du soudage peuvent facilement

passer dans d’autres zones en traversant de petites fissures et des

ouvertures.

Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.

Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-

clencher un incendie de l’autre côté.

Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-

voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés

correctement conformément à AWS F4.1 (voir les normes de sécurité).

Brancher le câble sur la pièce le plus près possible de la zone de soudage pour

éviter le transport du courant sur une longue distance par des chemins incon-

nus éventuels en provoquant des risques d’électrocution et d’incendie.

Brancher le câble de masse sur la pièce le plus près possible de la zone de

soudage pour éviter le transport du courant sur une longue distance par des

chemins inconnus éventuels en provoquant des risques d’électrocution,

d’étincelles et d’incendie.

Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.

En cas de non utilisation, enlever la baguette d’électrode du porte-électrode

ou couper le fil à la pointe de contact.

Porter des vêtements de protection dépourvus d’huile tels que des gants en

cuir, une chemise en matériau lourd, des pantalons sans revers, des chaus-

sures hautes et un couvre chef.

Avant de souder, retirer toute substance combustible de vos poches telles

qu’un allumeur au butane ou des allumettes.

Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B

pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.

DES PARTICULES VOLANTES

peuvent blesser les yeux.

Le soudage, l’écaillement, le passage de la pièce à la bros-

se en fil de fer, et le meulage génèrent des étincelles et des

particules métalliques volantes. Pendant la période de re-

froidissement des soudures, elles risquent de projeter du laitier.

Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

Ne pas toucher à mains nues les parties chaudes.

Prévoir une période de refroidissement avant de travailler à

l’équipement.

Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et por-

ter des gants de soudage et des vêtements épais pour éviter les brûlures.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affecter

l’ouïe.

Porter des protections approuvés pour les oreilles si le ni-

veau sonore est trop élevé.

LES CHAMPS MAGNÉTIQUES peuvent

affecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez à distance.

Les porteurs d’un stimulateur cardiaque doivent d’abord

consulter leur médecin avant de s’approcher des opéra-

tions de soudage à l’arc, de gougeage ou de soudage par

points.

Si des BOUTEILLES sont endomma-

gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous

haute pression. Si une bouteille est endommagée, elle peut

exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de

soudage, les manipuler avec précaution.

Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs

mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des

étincelles et des arcs.

Placer les bouteilles debout en les fixant dans un support stationnaire ou dans

un porte-bouteilles pour les empêcher de tomber ou de se renverser.

Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électri-

ques.

Ne jamais placer une torche de soudage sur une bouteille à gaz.

Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.

Ne jamais souder une bouteille pressurisée − risque d’explosion.

Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et rac-

cords convenables pour cette application spécifique; les maintenir ainsi que

les éléments associés en bon état.

Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.

Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou

de branchement de la bouteille.

Utiliser les équipements corrects, les bonnes procédures et suffisamment de

personnes pour soulever et déplacer les bouteilles.

Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement

connexe et le dépliant P-1 de la CGA (Compressed Gas Association) men-

tionné dans les principales normes de sécurité.

2-3. Dangers existant en relation avec le moteur

L’EXPLOSION DE LA BATTERIE peut

RENDRE AVEUGLE.

Toujours porter une protection faciale, des gants en caout-

chouc et vêtements de protection lors d’une intervention

sur la batterie.

Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.

Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie.

Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicu-

les de démarrage rapide.

Observer la polarité correcte (+ et −) sur les batteries.

Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier lieu.

LE CARBURANT MOTEUR peut provo-

quer un incendie ou une explosion.

Arrêter le moteur avant de vérifier le niveau de carburant

ou de faire le plein.

Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une

flamme nue.

Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son

expansion.

Faire attention de ne pas renverser de carburant. Nettoyer tout carburant

renversé avant de faire démarrer le moteur.

Jeter les chiffons dans un récipient ignifuge.

DES ORGANES MOBILES peuvent pro-

voquer des blessures.

Ne pas approcher les mains des ventilateurs, courroies et

autres pièces en mouvement.

Maintenir fermés et fixement en place les portes, panneaux, recouvre-

ments et dispositifs de protection.

Arrêter le moteur avant d’installer ou brancher l’appareil.

Seules des personnes qualifiées sont autorisées à enlever les portes, pan-

neaux, recouvrements ou dispositifs de protection pour effectuer, s’il y a lieu,

des travaux d’entretien et de dépannage.

Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,

débrancher le câble négatif (−) de batterie de la borne.

Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes

mobiles.

Remettre en place les panneaux ou les dispositifs de protection et fermer les

portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.

Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en

route accidentelle du moteur.

Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le

générateur.

DES PIECES CHAUDES peuvent provo-

quer des brûlures et blessures.

Ne pas toucher les parties chaudes du moteur.

Laisser l’ensemble se refroidir avant d’effectuer la

maintenance.

Porter des gants et des vêtements de protection pour travailler sur un

moteur chaud.

LA VAPEUR ET LE LIQUIDE DE

REFROIDISSEMENT CHAUD peuvent

provoquer des brûlures.

Il est préférable de vérifier le liquide de refroidissement

une fois le moteur refroidi pour éviter de se brûler.

Toujours vérifier le niveau de liquide de refroidissement dans le vase d’expan-

sion (si présent), et non dans le radiateur (sauf si précisé autrement dans la

section maintenance du manuel du moteur).

OM-4433 Page 7

Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.

Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon

du radiateur.

Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle-

ver le bouchon.

LES ACCUMULATIONS DE GAZ ris-

quent de provoquer des blessures ou

même la mort.

Fermer l’alimentation du gaz protecteur en cas de non

utilisation.

Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-

rateur d’adduction d’air homologué.

L’ACIDE DE LA BATTERIE peut pro-

voquer des brûlures dans les YEUX et

sur la PEAU.

Ne pas renverser la batterie.

Remplacer une batterie endommagée.

Rincer immédiatement les yeux et la peau à l’eau.

LA CHALEUR DU MOTEUR peut pro-

voquer un incendie.

Ne pas placer l’appareil sur, au-dessus ou à proximité de

surfaces inflammables.

Tenir à distance les produits inflammables de l’échappement.

LES ÉTINCELLES À L’ÉCHAPPEMENT

peuvent provoquer un incendie.

Empêcher les étincelles d’échappement du moteur de

provoquer un incendie.

Utiliser uniquement un pare-étincelles approuvé − voir

codes en vigueur.

2-4. Dangers liés à l’air comprimé

RESPIRER L’AIR COMPRIMÉ peut pro-

voquer des blessures graves ou causer

la mort.

Ne pas utiliser l’air comprimé pour respirer.

Utiliser l’air comprimé seulement pour le coupage, gou-

geage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer

des blessures.

Porter des lunettes de sécurité approuvées.

Ne pas diriger le jet d’air vers d’autres ou soi-même.

L’AIR COMPRIME EMMAGASINE ET DES

TUYAUX SOUS PRESSION peuvent provo-

quer des blessures.

Relâcher la pression d’air de l’outillage ou du systè-

me avant d’effectuer la maintenance, avant de chan-

ger ou de rajouter des éléments ou avant d’ouvrir la

purge ou le bouchon de remplissage d’huile.

Le METAL CHAUD lors du coupage et

gougeage plasma peut provoquer un in-

cendie ou une explosion.

Ne pas couper ou gouger à proximité de produits in-

flammables.

Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provo-

quer des brûlures et blessures.

Ne pas toucher le compresseur ou d’autres éléments

du circuit air comprimé chauds.

Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la mainte-

nance.

LIRE LES INSTRUCTIONS.

Lisez le manuel d’instructions avant l’utilisation ou la

maintenance de l’appareil.

Arrêter le moteur et relâcher la pression avant d’ef-

fectuer la maintenance.

Utiliser uniquement des pièces de rechange Miller/Hobart.

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

LA CHUTE DE L’APPAREIL peut blesser.

Utiliser un œilleton de levage pour lever l’appareil et les

accessoires correctement installés. Ne pas dépasser

le poids nominal maximal de l’œilleton (voir les

spécifications).

Ne lever et ne soutenir l’appareil qu’avec de l’équipement

approprié et en suivant les procédures adéquates.

En utilisant des fourches de levage pour déplacer l’unité, s’assurer que

les fourches sont suffisamment longues pour dépasser du côté opposé

de l’appareil.

LE SURCHAUFFEMENT peut endom-

mager le moteur électrique.

Arrêter ou déconnecter l’équipement avant de démarrer ou

d’arrêter le moteur.

Ne pas laisser tourner le moteur trop lentement sous risque d’endommager

le moteur électrique à cause d’une tension et d’une fréquence trop faibles.

Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a

lieu.

LES ÉTINCELLES VOLANTES risquent

de provoquer des blessures.

Porter un écran facial pour protéger le visage et les yeux.

Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protec-

teurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte

l’équipement homologué de protection du visage, des mains et du corps.

Les étincelles risquent de causer un incendie − éloigner toute substance in-

flammable.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

Laisser l’équipement refroidir ; respecter le facteur de

marche nominal.

Réduire le courant ou le facteur de marche avant de

poursuivre le soudage.

Ne pas obstruer les passages d’air du poste.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les

circuits imprimés.

Établir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pièces.

Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer

ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut

entraîner des blessures.

Utiliser les supports de la remorque ou des blocs pour

soutenir le poids.

Installer convenablement le poste sur la remorque com-

me indiqué dans le manuel s’y rapportant.

OM-4433 Page 8

LIRE LES INSTRUCTIONS.

Utiliser seulement les pièces de rechange d’origine.

Effectuer la maintenance du moteur et du compresseur

(si applicable) suivant ce manuel et le manuel du moteur/

compresseur (si applicable).

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer

des interférences.

Le rayonnement haute fréquence (H.F.) peut provoquer

des interférences avec les équipements de

radio−navigation et de communication, les services de

sécurité et les ordinateurs.

Demander seulement à des personnes qualifiées familiarisées avec des

équipements électroniques de faire fonctionner l’installation.

L’utilisateur est tenu de faire corriger rapidement par un électricien quali-

fié les interférences résultant de l’installation.

Si le FCC signale des interférences, arrêter immédiatement l’appareil.

Effectuer régulièrement le contrôle et l’entretien de l’installation.

Maintenir soigneusement fermés les portes et les panneaux des sources

de haute fréquence, maintenir les éclateurs à une distance correcte et

utiliser une terre et un blindage pour réduire les interférences

éventuelles.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

L’énergie électromagnétique risque de provoquer des in-

terférences pour l’équipement électronique sensible tel

que les ordinateurs et l’équipement commandé par ordi-

nateur tel que les robots.

Veiller à ce que tout l’équipement de la zone de soudage soit compatible

électromagnétiquement.

Pour réduire la possibilité d’interférence, maintenir les câbles de souda-

ge aussi courts que possible, les grouper, et les poser aussi bas que pos-

sible (ex. par terre).

Veiller à souder à une distance de 100 mètres de tout équipement élec-

tronique sensible.

Veiller à ce que ce poste de soudage soit posé et mis à la terre conformé-

ment à ce mode d’emploi.

En cas d’interférences après avoir pris les mesures précédentes, il in-

combe à l’utilisateur de prendre des mesures supplémentaires telles que

le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil-

tres de ligne ou la pose de protecteurs dans la zone de travail.

2-6. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des fumées et

des gaz qui contiennent des produits chimiques dont l’État de Californie

reconnaît qu’ils provoquent des malformations congénitales et, dans

certains cas, des cancers. (Code de santé et de sécurité de Californie,

chapitre 25249.5 et suivants)

Les batteries, les bornes et autres accessoires contiennent du plomb et

des composés à base de plomb, produits chimiques dont l’État de Cali-

fornie reconnaît qu’ils provoquent des cancers et des malformations

congénitales ou autres problèmes de procréation. Se laver les mains

après manipulation.

Pour les moteurs à essence :

Les gaz d’échappement des moteurs contiennent des produits chimi-

ques dont l’État de Californie reconnaît qu’ils provoquent des cancers

et des malformations congénitales ou autres problèmes de procréation.

Pour les moteurs diesel :

Les gaz d’échappement des moteurs diesel et certains de leurs compo-

sants sont reconnus par l’État de Californie comme provoquant des

cancers et des malformations congénitales ou autres problèmes de pro-

création.

2-7. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

de Global Engineering Documents (téléphone : 1-877-413-5184, site In-

ternet : www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cutting

of Containers and Piping, American Welding Society Standard AWS F4.1

de Global Engineering Documents (téléphone : 1-877-413-5184, site In-

ternet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protection

Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA

02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de

Compressed Gas Association, 1735 Jefferson Davis Highway, Suite

1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet

: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, de

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :

800-463-6727 ou à Toronto 416-747-4044, site Internet :

www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, de American National Standards Institute, 11 West

42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site

Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, de National Fire Protection Association, P.O.

Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :

617-770-3000, site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Industry,

Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and

Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent

of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux

régionaux−−le téléphone de la région 5, Chicago, est 312-353-2220, site

Internet : www.osha.gov).

2-8. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des

champs magnétiques et électriques.

Le courant de soudage, pendant son passage dans les câbles de souda-

ge, causera des champs électromagnétiques. Il y a eu et il y a encore un

certain souci à propos de tels champs. Cependant, après avoir examiné

plus de 500 études qui ont été faites pendant une période de recherche

de 17 ans, un comité spécial ruban bleu du National Research Council a

conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a

pas démontré que l’exposition aux champs magnétiques et champs élec-

triques à haute fréquence représente un risque à la santé humaine ».

Toutefois, des études sont toujours en cours et les preuves continuent à

être examinées. En attendant que les conclusions finales de la recherche

soient établies, il vous serait souhaitable de réduire votre exposition aux

champs électromagnétiques pendant le soudage ou le coupage.

Pour réduire les champs magnétiques sur le poste de travail, appliquer les

procédures suivantes :

1. Maintenir les câbles ensemble en les tordant ou en les envelop-

pant.

2. Disposer les câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4. Garder le poste de soudage et les câbles le plus loin possible de

vous.

5. Connecter la pince sur la pièce aussi près que possible de la sou-

dure.

En ce qui concerne les stimulateurs cardiaques

Les porteurs de stimulateur cardiaque doivent consulter leur médecin

avant de souder ou d’approcher des opérations de soudage. Si le médecin

approuve, il est recommandé de suivre les procédures précédentes.

OM-4433 Page 9

SECTION 3 − DEFINITIONS

3-1. Warning Label Definitions

3/96

1 Remove unit from shipping

crate. Remove Owner’s

Manual from unit. Follow

instructions to install muffler.

2 Read Owner’s Manual. Read

labels on unit.

3 Use Diesel Fuel only, and fill

fuel tank. Leave room for

expansion.

4 Warning! Watch Out! There

are possible hazards as

shown by the symbols. Read

Owner’s Manual. Follow

instructions to activate

battery.

5 Check oil level. Add oil if

necessary.

6 During the first 50 hours of

operation, keep welding load

above 200 amperes. Do not

weld below 200 amperes of

output.

7 After the first 50 hours of

operation, change the oil and

oil filter.

+

2

1+

4

DIESEL

API CD-MIL L 2104D,

CD/SE, CD/SF

3

S-177 571

0 − 50 h Std. 0 − 200A

200A

5

50 h Std.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4433 Page 10

3-2. Manufacturer’s Rating Label

Ref. 218 304-A

OM-4433 Page 11

3-3. Symbols And Definitions

Some symbols are found only on CE products.

NOTE

Stop Engine Fast (Run, Weld/

Power) Slow (Idle) Start Engine

Starting Aid

(Preheat) Battery (Engine) Engine Oil

Pressure Engine Oil

Check Injectors/

Pump Check Valve

Clearance Fuel Protective Earth

(Ground)

Positive Negative Certified/Trained

Mechanic Welding Arc

AAmperes VVolts Panel/Local Remote

Engine Air Temperature Or

Engine

Temperature Output Alternating

Current

Stick (SMAW)

Welding Constant Current

(CC) MIG (GMAW)

Welding TIG (GTAW)

Time hHours sSeconds 1Single Phase

3Three Phase Read Operator’s

Manual Circuit Protector Do Not Switch

While Welding

Electrode

Connection Work Connection 3

G

Engine-Driven,

Three-Phase

Alternator With

Rectifier Hz Hertz

XDuty Cycle U0Rated No Load

Voltage (Average) U2Conventional

Load Voltage nRated Load

Speed

n1Rated Idle

Speed n0Rated No Load

Speed ICurrent I2Rated Welding

Current

Contactor On Arc Force (Dig) Lift-Arc TIG

OM-4433 Page 12

SECTION 4 − SPECIFICATIONS

4-1. Weld, Power, And Engine Specifications

Welding

Mode Weld Output

Range Rated Welding

Output

Maximum

Open-

Circuit

Voltage

Generator Power

Rating Engine Fuel

Capacity

CC/DC

20 − 410 A

400 A, 23 Volts DC,

40% Duty Cycle

300 A, 32 Volts DC

CC/DC

20 410 A

(CC Models)

300 A

,

32 Volts DC

60% Duty Cycle

250 A, 30 Volts DC

100% Duty cycle

65

Single-Phase,

10 kVA/kW, 84/42 A, Perkins 403C-15

Wat C l d

Perkins

11.5 gal

CV/DC

(CC/CV

Models

Only)

14 − 40 V

400 A, 23 Volts DC,

30% Duty Cycle

300 A, 29 Volts DC

60% Duty Cycle

250 A, 26.5 Volts DC

100% Duty cycle

6

5

10 kVA/kW

,

84/42 A

,

120/240 V AC,

60 Hz

Water-Cooled,

Three-Cylinder,

21.7 HP Diesel Engine

11.5 gal

(43.5 L)

4-2. Dimensions, Weights, And Operating Angles

Dimensions

Height 32 in (813 mm)

35-3/4 in (908 mm)

(to top of lift eye) G

Width

26-1/4 in (667 mm)

(mtg. brackets turned in)

28-3/4 in (730 mm)

(mtg. brackets turned out)

Do not exceed tilt angles or engine could

be damaged or unit could tip.

Do not move or operate unit where it could

tip.

Depth 56 in (1422 mm)

tip

.

A56 in (1422 mm)

B54 in (1372 mm)

B

A

C

C52 in in (1321 mm) B

A

C

D2 in (51 mm)

E26 in (660 mm)

F7/8 in (22 mm) 30°

G27-3/4 in (705 mm)

20

°30°

H9/16 in (14 mm) Dia.

4 Holes Front Panel End

H20

°

20°

Weight

F

D

No fuel: 1100 lb (499 kg)

w/ fuel: 1199 lb (544 kg)

F

E

D

Lifitng Eye Weight Rating:

1500 lb (680 Kg) Maximum

OM-4433 Page 13

4-3. Volt-Ampere Curves

217 517 / 217 516 / 217 518

The volt-ampere curves show the

minimum and maximum voltage

and amperage output capabilities of

the welding generator. Curves of all

other settings fall between the

curves shown.

A. Stick Mode

B. MIG Mode

C. TIG Mode

DC VOLTS

DC AMPERES

0 100 200 300 400 500

100

90

80

70

60

50

40

30

20

10

0

MIN MAX

300

0 100 200 300 400 500

100

80

60

40

20

0

DC VOLTS

DC AMPERES

DC VOLTS

DC AMPERES

0 100 200 300 400 500

100

80

60

40

20

0

MIN MAX300

OM-4433 Page 14

4-4. Fuel Consumption

The curve shows typical fuel use

under weld or power loads.

217 509

IDLE

DC WELD AMPERES AT 100% DUTY CYCLE

U.S. GAL/HR.

0.00

0.25

0.50

0.75

1.00

1.25

1.50

1.75

2.00

0 50 100 150 200 250 300 350 400

Continuous Welding

4-5. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

Exceeding duty cycle can

damage unit and void

warranty.

100% Duty Cycle At 250 Amperes

217 515

10 15 20 25 30 40 50 60 80 100

CC

CV

1000

800

600

500

400

300

250

200

150

100

WELD AMPERES

% DUTY CYCLE

OM-4433 Page 15

4-6. AC Generator Power Curve

217 519

The ac power curve shows the gen-

erator power in amperes available

at the 120 and 240 volt receptacles.

0 40 80 120 160

0 20406080

AC AMPERES IN 120 V MODE

AC AMPERES IN 240 V MODE

300

250

200

150

100

50

0

150

125

100

75

50

25

0

AC VOLTS

Notes

16 Gauge (.063 in)

22 Gauge (.031 in)

24 Gauge (.025 in)

20 Gauge (.037 in)

18 Gauge (.050 in)

14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

MATERIAL THICKNESS REFERENCE CHART

OM-4433 Page 16

SECTION 5 − INSTALLATION

install3 8/06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

Always securely fasten weld-

ing generator onto transport

vehicle or trailer and comply

with all DOT and other applica-

ble codes.

Always ground generator

frame to vehicle frame to pre-

vent electric shock and static

electricity hazards.

If unit does not have GFCI re-

ceptacles, use GFCI-protected

extension cord.

Do not install unit where air

flow is restricted or engine

may overheat.

See Section 4-2 for lifting eye

rating.

See Section 5-2 for mounting

information.

Grounding:

1 Equipment Grounding Terminal

(On Front Panel)

2 Grounding Cable (Not Supplied)

3 Metal Vehicle Frame

Connect cable from equipment

ground terminal to metal vehicle

frame. Use #10 AWG or larger insu-

lated copper wire.

Electrically bond generator frame to

vehicle frame by metal-to-metal contact.

GND/PE

1

2

3

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm) 18 in

(460 mm)

18 in

(460 mm)

Movement

5

-1. Installing Welding Generator

OR

Grounding

Bed liners, shipping skids, and some running

gears insulate the welding generator from the

vehicle frame. Always connect a ground wire

from the generator equipment grounding termi-

nal to bare metal on the vehicle frame as shown.

OR

Location/Airflow Clearance

OR

OM-4433 Page 17

5-2. Mounting Welding Generator

Tools Needed:

9/16 in

2

2

4

Welding Unit In Place

Bolting Unit In Place

Do not weld on base. Weld-

ing on base can cause fuel

tank fire or explosion. Weld

only on the four mounting

brackets or bolt unit down.

Do not mount unit by sup-

porting the base only at the

four mounting brackets.

Use cross-supports to ade-

quately support unit and pre-

vent damage to base.

Mounting Surface:

1 Cross-Supports

2 Mounting Brackets (Supplied)

Mount unit on flat surface or use

cross-supports to support base.

Secure unit with mounting brack-

ets.

3 1/2 in Bolt And Washer

(Minimum − Not Supplied)

4 3/8-16 x 1 in Screws

(Supplied)

To Bolt Unit In Place:

Remove hardware securing the

four mounting brackets to the base.

Reverse brackets and reattach to

base with original hardware.

Mount unit to truck or trailer with 1/2

in (12 mm) or larger hardware (not

supplied).

To Weld Unit In Place:

Weld unit to truck or trailer only at

the four mounting brackets.

1

Inadequate support.

2

Supporting The Unit

Using Mounting Brackets

install3 8/06 803 274 / 200 864-A / 803 562

Do not use flexible mounts.

1

OR

3

OM-4433 Page 18

5-3. Installing Exhaust Pipe

1/2 in

Tools Needed:

803 582 / Ref. 217 357-A

Stop engine and let cool.

Point exhaust pipe in desired di-

rection but always away from front

panel and direction of travel.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4433 Page 19

5-4. Activating The Dry Charge Battery (If Applicable)

Always wear a face shield,

rubber gloves and protective

clothing when working on a

battery.

Remove battery from unit.

5 Vent Caps

6 Sulfuric Acid Electrolyte

(1.265 Specific Gravity)

7 Well

Fill each cell with electrolyte to

bottom of well (maximum).

Do not overfill battery cells.

Wait ten minutes and check electro-

lyte level. If necessary, add electro-

lyte to raise to proper level. Reins-

tall vent caps.

8 Battery Charger

Read and follow all instruc-

tions supplied with battery

charger.

Charge battery for 12 minutes at 30

amperes or 30 minutes at 5 am-

peres. Disconnect charging cables

and install battery.

When electrolyte is low, add

only distilled water to cells to

maintain proper level.

1

Tools Needed:

2

4

30 A For 12 Minutes

5 A For 30 Minutes

OR +

−

3

drybatt1 6/05 − S-0886

5-5. Connecting The Battery

1/2 in

−

+

Connect Negative (−) Cable Last.

Tools Needed:

803 563 / Ref. 217 357-A / S-0756-C

Close door after connecting battery.

OM-4433 Page 20

5-6. Engine Prestart Checks

Check all engine fluids daily.

Engine must be cold and on a level surface.

Unit is shipped with 20W break-in oil.

Automatic shutdown system stops engine if

oil pressure is too low or coolant tempera-

ture is too high.

This unit has a low oil pressure shut-

down switch. However, some condi-

tions may cause engine damage before

the engine shuts down. Check oil level

often and do not use the oil pressure

shutdown system to monitor oil level.

Follow run-in procedure in engine manual.

If unburned fuel and oil collect in exhaust

pipe during run-in, see Section 10.

Fuel

Do not use gasoline. Gasoline will

damage engine.

The unit is shipped with enough fuel to pre-

vent air from entering fuel system. Add fresh

diesel fuel before starting (see engine main-

tenance label for fuel specifications). Leave

filler neck empty to allow room for

expansion.

Do not run out of fuel or air will enter fuel sys-

tem and cause starting problems. See en-

gine manual to bleed air from fuel system.

Oil

After fueling, check oil with unit on level sur-

face. If oil is not up to full mark on dipstick,

add oil (see maintenance label).

Coolant

Check coolant level in radiator before start-

ing unit the first time. If necessary, add cool-

ant to radiator until coolant level is at bottom

of filler neck.

Check coolant level in recovery tank daily.

If necessary, add coolant to recovery tank

until coolant level is between Cold Full and

Hot Full levels. If recovery tank coolant level

was low, also check coolant level in radiator.

Add coolant if level is below bottom of radia-

tor filler neck.

Unit is shipped with an engine coolant mix-

ture of water and ethylene glycol base anti-

freeze rated to −34° F (−37° C). Add anti-

freeze to mixture if using the unit in tempera-

tures below −34° F (−37° C).

Keep radiator and air intake clean and free

of dirt.

Incorrect engine temperature can

damage engine. Do not run engine

without a properly working thermo-

stat and radiator cap.

To improve cold weather starting:

Use Preheat switch (see Section 6-1).

Keep battery in good condition. Store

battery in warm area.

Use fuel formulated for cold weather

(diesel fuel can gel in cold weather).

Contact local fuel supplier for fuel in-

formation.

Use correct grade oil for cold weather

(see Section 8-2).

Full

Full

Capacity:

6 qt (5.7 L)

Diesel

Full

Hot Full

Cold Full

Check radiator coolant

level when fluid is low in

recovery tank.

Coolant Recovery Tank

803 563

OM-4433 Page 21

5-7. Connecting To Weld Output Terminals

803 562 / 803 778-A

Tools Needed:

3/4 in

MIG and FCAW Welding

For MIG and FCAW welding Direct Current

Electrode Positive (DCEP) connect wire feed-

er cable to CV (Wire) terminal on right and

work cable to Work/Negative (−) terminal on

left. Use Process/Contactor switch to select

type of weld output (see Section 6-3).

For Direct Current Electrode Negative

(DCEN), reverse cable connections.

7

5

6

Do not place

anything between

Correct Installation Incorrect Installation

4

weld cable terminal

and copper bar.

Stop engine.

1 Work/Negative (−) Weld Output Terminal

2 CV (wire) Weld Output Terminal

3 CC (Stick/TIG) Weld Output Terminal

Failure to properly connect weld

cables may cause excessive heat and

start a fire, or damage your machine.

4 Weld Output Terminal

5 Supplied Weld Output Terminal Nut

6 Weld Cable Terminal

7 Copper Bar

Remove supplied nut from weld output termi-

nal. Slide weld cable terminal onto weld output

terminal and secure with nut so that weld cable

terminal is tight against copper bar. Do not

place anything between weld cable termi-

nal and copper bar. Make sure that the sur-

faces of the weld cable terminal and cop-

per bar are clean.

Stick and TIG Welding

For Stick and TIG welding Direct Current Elec-

trode Positive (DCEP), connect electrode

holder cable to CC (Stick/TIG) terminal on

right and work cable to Work/Negative (−) ter-

minal on left.

For Direct Current Electrode Negative

(DCEN), reverse cable connections.

Use Process/Contactor switch to select type

of weld output (see Section 6-3).

1

2

3

123

OM-4433 Page 22

5-8. Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

100 ft (30 m) or Less 150 ft

(45 m) 200 ft

(60 m) 250 ft

(70 m) 300 ft

(90 m) 350 ft

(105 m) 400 ft

(120 m)

Weld Output

Terminals

Stop engine before

connecting to weld out-

put terminals.

Do not use worn, dam-

aged, undersized, or

poorly spliced cables.

Welding

Amperes

10 − 60%

Duty

Cycle

60 − 100%

Duty

Cycle 10 − 100% Duty Cycle

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0

(2x70) 2 ea. 2/0

(2x70)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 3/0

(2x95)

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 3/0

(2x95) 2 ea. 4/0

(2x120)

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 4/0

(2x120) 2 ea. 4/0

(2x120)

500 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0

(2x70) 2 ea. 3/0

(2x95) 2 ea. 4/0

(2x120) 3 ea. 3/0

(3x95) 3 ea. 3/0

(3x95)

* This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm2 for metric use S-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

Notes

OM-4433 Page 23

5-9. Connecting To Remote 14 Receptacle RC14

Socket* Socket Information

24 VOLTS AC

A24 volts ac. Protected by sup-

plementary protector CB8.

24 VOLTS AC

BContact closure to A completes

24 volt ac contactor control

circuit.

COutput to remote control:+10

volts dc in MIG mode; 0 to +10

volts dc in Stick or TIG mode.

REMOTE

OUTPUT

DRemote control circuit common.

LDR-14 long

distance remote

(includes 120 V

receptacle)

OUTPUT

CONTROL EDC input command signal: 0 to

+10 volts from min. to max. of

remote control with Voltage/

Amperage Adjust control at

max.

p)

115 VOLTS AC I115 volts, 10 amperes, 60 Hz

ac. Protected by supplementary

protector CB7.

OR

JContact closure to I completes

115 volt ac contactor control

circuit.

OR

FCurrent feedback: 1 volt per

100 amperes.

HVoltage feedback: 1 volt per 10

arc volts.

803 562 GND K Chassis common.

NEUTRAL G Circuit common for 24 and 115

volt ac circuit.

*The remaining sockets are not used.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4433 Page 24

SECTION 6 − OPERATING WELDING GENERATOR

6-1. Front Panel Controls (See Section 6-2)

217 357-B / 803 563

1254

678

910

3

OM-4433 Page 25

6-2. Description Of Front Panel Controls (See Section 6-1)

Engine Starting Controls

1 Preheat Switch

Use switch to energize starting aid for cold

weather starting (see starting instructions fol-

lowing).

2 Engine Control Switch

Use switch to start engine, select engine

speed (if unit has auto idle option), and stop

engine.

In Run position, engine runs at weld/power

speed. In Auto position (optional), engine

runs at idle speed at no load and weld speed

with load applied.

3 Engine Stop Lever

Use lever to stop engine if Engine Control

switch does not work.

The Engine Stop lever shuts off the fuel

supply. However, the Engine Stop lever

will not stop the engine if the engine can

draw fuel-rich air from the surrounding

atmosphere (oil refineries).

To Start:

Do not use ether.

If engine does not start, let engine come

to a complete stop before attempting re-

start.

Above 325 F (05 C): turn Engine Control

switch to Start. Release Engine Control

switch when engine starts.

Below 325 F (05 C): turn engine control switch

to Auto position. Push Preheat switch up for

60 seconds. Turn Engine Control switch to

Start. Release Engine Control switch and

Preheat switch when engine starts.

To Stop: turn Engine Control switch to Off

position.

Engine Gauges, Meters, And Lights

4 Fuel Gauge/Hourmeter

Use gauge to check fuel level or total engine

operating hours.

To check fuel level or engine hours when en-

gine is not running, turn Engine Control switch

to Run or Auto (optional) position.

5 Engine Indicator Light

Light goes on and engine stops if engine tem-

perature exceeds 230°F (110° C) or engine

oil pressure is below 10 psi (69 kPa).

Normal engine temperature is 180 - 203

F (82 - 95 C). Normal oil pressure is 30

- 60 psi (207 - 414 kPa).

Do not run engine until trouble is

fixed.

Weld Controls

6 Remote Control Receptacle

Use receptacle to connect remote controls,

wire feeders, and tools.

When a remote control is connected to the

Remote receptacle, the Auto Sense Remote

feature automatically switches voltage/am-

perage control to the remote control (see Sec-

tion 5-9).

With remote control connected, weld output is

determined by a combination of front panel

and remote control voltage/amperage set-

tings.

If no remote control is connected to the Re-

mote receptacle, the front panel Voltage/Am-

perage control adjusts voltage and amper-

age.

If a remote device connected to Remote

Receptacle RC14 is faulty or is discon-

nected, the meters display Help 25 (see

Section 8-11). Clear fault by stopping and

restarting the unit or by turning Process/

Contactor switch to another position.

7 Process/Contactor Switch

See Section 6-3 for Process/Contactor

switch information.

8 Voltage/Amperage Control

With Process/Contactor switch in any Stick or

TIG setting, use control to adjust amperage.

With Process/Contactor switch in any Wire

(MIG) position, use control to adjust voltage.

With Voltage/Amperage Adjust Switch in Re-

mote position, control limits the remote am-

perage in Stick or TIG mode, but has no effect

in Wire (MIG) modes.

Weld Meters

Weld meters also work in combination to

display troubleshooting help codes (see

Section 8-11).

9 DC Voltmeter

Voltmeter displays preset voltage (MIG weld-

ing) with contactor off, and actual output volt-

age with the contactor on. Voltmeter displays

voltage at the weld output terminals, but not

necessarily the welding arc due to resistance

of cable and connections.

To set voltage, turn contactor off and turn Pro-

cess/Contactor switch to Wire position. Turn

V/A control until desired voltage is displayed

on Voltmeter. When welding is finished, volt-

meter displays weld voltage and then defaults

to preset voltage.

10 DC Ammeter

Ammeter displays preset amperage (Stick

and TIG only) when not welding, and actual

output amperage when welding.

To set amperage, turn Process/Contactor

switch to Stick or TIG position. Turn V/A con-

trol until desired amperage is displayed on

Ammeter. When welding is finished, ammeter

displays weld amperage and then defaults to

preset amperage.

OM-4433 Page 26

6-3. Process/Contactor Switch

1 Process/Contactor Switch

Weld output terminals are ener-

gized when Process/Contactor

switch is in a Weld Terminals Al-

ways On position and the engine

is running.

Use switch to select weld process and

weld output on/off control (see table be-

low).

Place switch in Remote On/Off Switch

Required positions to turn weld output on

and off with a device connected to the

Remote 14 receptacle.

Place switch in Weld Terminals Always

On positions for weld output to be on

whenever the engine is running.

Use Stick mode for air carbon arc

(CAC-A) cutting and gouging.

When switch is in Stick mode, select one

of four arc drive (dig) settings to provide

additional amperage during low voltage

(short arc length) conditions and prevent

“sticking” electrodes. Turn control from A

to D to increase arc drive (dig) from min

to max.

Use the Lift-Arc TIG mode for TIG

(GTAW) welding using the Lift-Arc TIG

starting procedure (see Section 6-4).

1

803 562 / 217 357

Process/Contactor Switch Settings

Switch Setting

Process

Output On/Off Control

Engine Auto Idle (Optional)

Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)

Remote On/Off Switch Re-

quired −TIG HF Required Or

Scratch Start

GTAW With HF Unit, Pulsing

Device, Or Remote Control At Remote 14 Receptacle Active

Remote On/Off Switch

Required − Stick Stick (SMAW) With Remote On/Off At Remote 14 Receptacle Active

Remote On/Off Switch

Required − CV Feeder

Using Remote

MIG (GMAW)

w/Constant Speed Feeder At Remote 14 Receptacle Active

Weld Terminals Always On −

Wire MIG (GMAW)

w/Voltage Sensing Feeder Electrode Hot Active

Weld Terminals Always On −

Stick

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting

And Gouging Electrode Hot Active

Weld Terminals Always On −

TIG Lift-Arc TIG Lift-Arc (GTAW) Electrode Hot Active

OM-4433 Page 27

6-4. Lift-Arc™ Start Procedure

Lift-Arc  TIG

With Lift-Arc TIG selected, start

arc as follows:

1 TIG Electrode

2 Workpiece

Turn gas on. Touch tungsten

electrode to workpiece at weld start

point. Hold electrode to

workpiece for 1-2 seconds, and

slowly lift electrode. Arc is formed

when electrode is lifted.

Normal open-circuit voltage is not

present before tungsten electrode

touches workpiece; only a low

sensing voltage is present between

electrode and workpiece. The

solid-state output contactor does

not energize until after electrode is

touching workpiece. This allows

electrode to touch workpiece

without overheating, sticking, or be-

ing contaminated.

Application:

Lift-Arc is used for the DCEN

GTAW process when HF Start

method is not permitted, or to

replace the scratch method.

1

1 − 2

Seconds

“Touch”

Do NOT Strike Like A Match!

2

Lift-Arc Start Method

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4433 Page 28

6-5. Remote Voltage/Amperage Control

1 Remote 14 Receptacle RC14

Connect optional remote control to RC14 (see

Section 5-9).

When a remote control is connected to the

Remote receptacle, the Auto Sense Re-

mote feature automatically switches volt-

age/amperage control to the remote con-

trol. When a device is connected to the Re-

mote receptacle, remote voltage/amper-

age control is always available regardless

of the position of the Process/Contactor

switch.

0774 / Ref.217 357−B / 803 562

Adjust Optional Remote

Control to 100%

Set V/A Control

To Desired Maximum

Weld Output Using Weld

Meters

Set TIG or STICK Process

In Example:

Min = 20 A DC

Max = 205 A DC

Max (205 A DC)

Min (20 A DC)

Connect Remote

Control To Remote

Receptacle RC14

1

Adjust Optional Remote

Control to desired

weld output

Weld meters will always

show the combined main

and remote control setting

and machine welds at

nominal output setting of

the meter.

Weld meters show preset

output when not welding.

Set WIRE Process

Connect Remote

Control To Remote

Receptacle RC14

Adjust Optional Remote

Control to desired

weld output

OM-4433 Page 29

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Receptacles

217 357-A

1 120 V 20 A AC (shown)

Receptacle RC5 and/or GFCI1

2 120 V 20 A AC GFCI (shown)

Receptacle RC6 and/or GFCI2

3 240 V 50 A AC

Receptacle RC11

RC5 / 6 and GFCI1 / 2 supply 60 Hz single-

phase power at weld/power speed. Recep-

tacle configuration varies depending on

machine model and serial number.

Maximum output from these receptacles is

2.4 kVA/kW.

If a ground fault is detected, GFCI Reset

button pops out and receptacle does not

work. Check for faulty equipment plugged

in receptacle. Press button to reset GFCI

receptacle.

At least once a month, run engine at

weld/power speed and press test but-

ton to verify GFCI is working properly.

RC11 supplies 60 Hz single-phase power

at weld/power speed. Maximum output

from RC11 is 10 kVA/kW.

4 Supplementary Protector CB4

5 Supplementary Protector CB6

6 Supplementary Protector CB5

CB4 protects RC6 / GFCI2 and CB6 pro-

tects RC5 / GFCI1 from overload. If a sup-

plementary protector opens, the receptacle

does not work. Press button to reset.

Supplementary protector CB5 protects re-

ceptacles and the generator winding from

overload. If CB5 opens, the receptacles do

not work. Place CB5 switch in On position

to reset circuit breaker.

If a supplementary protector continues

to open, contact Factory Authorized

Service Agent.

Generator power decreases as weld

output increases.

Combined output of all receptacles is limit-

ed to the 10 kVA/kw rating of the generator.

EXAMPLE: If 15 A is drawn from each 120

V receptacle , only 26 A is available at the

240 V receptacle:

2 x (120 V x 15 A) + (240 V x 26 A) =

10.0 kVA/kW

1 2 3456

OM-4433 Page 30

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

Stop engine before maintaining.

See Engine Manual and Maintenance Label

for important start-up, service, and storage

information. Service engine more often if

used in severe conditions.

Recycle engine

fluids.

 = Check  = Change  = Clean  = Replace

* To be done by Factory Authorized Service Agent Reference

Every

8

Hours

Section 5-6,

8-8

 Coolant Level  Fuel Level  Oil Level  Oil, Fuel Spills

Every

50

Hours

Section 8-3

 Air Cleaner Element  Weld Terminals

Every

100

Hours

 Battery Terminals  Air Cleaner Hoses

Every

250

Hours

1/2 in.

(13 mm)

Engine

Manual,

Section 8-4

 Unreadable Labels  Fan Belt Tension  Oil  Oil Filter Spark Arrestor

Every

500

Hours

 Weld Cables  FuelFilter  Inline Fuel Filter

Every

1000

Hours OR

SLUDGE

FUEL Section 5-6,

8-10, 8-8

and Engine

Manual

Radiator Fluid Level  Inside Unit Valve Clearance*  Drain Sludge

 Slip Rings*

 Brushes*

Every

2000

Hours

 Injectors*

OM-4433 Page 31

8-2. Maintenance Label

OM-4433 Page 32

8-3. Servicing Air Cleaner

Stop engine.

Do not run engine without air

cleaner or with dirty element. En-

gine damage caused by using a

damaged element is not covered

by the warranty.

The air cleaner primary element can

be cleaned but the dirt holding capac-

ity of the filter is reduced with each

cleaning. The chance of dirt reaching

the clean side of the filter while clean-

ing and the possibility of filter damage

makes cleaning a risk. Consider the

risk of unwarrantable equipment

damage when determining whether

to clean or replace the primary ele-

ment.

If you decide to clean the primary ele-

ment, we strongly recommend instal-

ling an optional safety element to pro-

vide additional engine protection.

Never clean a safety element. Re-

place the safety element after servic-

ing the primary element three times.

Clean or replace primary element if dirty

(see note above before cleaning). Re-

place primary element if damaged. Re-

place primary element yearly or after six

cleanings.

1 Housing

2 Safety Element (Optional)

3 Primary Element

4 Dust Cap

5 Dust Ejector

To clean air filter:

Wipe off cap and housing. Remove cap

and dump out dust. Remove element(s).

Wipe dust from inside cap and housing

with damp cloth. Reinstall safety element

(if present). Reinstall cap.

Do not clean housing with air

hose.

Clean primary element with compressed

air only.

Air pressure must not exceed 100 psi

(690 kPa). Use 1/8 in (3 mm) nozzle and

keep nozzle at least 2 in (51 mm) from

inside of element. Replace primary ele-

ment if it has holes or damaged gaskets.

Reinstall primary element and cap (dust

ejector down).

Blow Inspect

41 3

5

Keep nozzle

2 in (51 mm)

from element.

2

aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 217 357-A

Optional

OM-4433 Page 33

8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler

803 582 / Ref. 217 357-A

Stop engine and let cool.

1 Spark Arrestor Muffler

2 Cleanout Plug

Remove plug and remove any dirt

covering cleanout hole.

3 Exhaust Pipe

Start engine and run at idle speed to

blow out cleanout hole. If nothing

blows out of hole, briefly cover end

of exhaust pipe with fireproof

material.

Stop engine and let cool.

Reinstall cleanout plug.

Tools Needed:

3/8 in

1

2

3

8-5. Servicing Engine Cooling System

803 563

Stop engine and let cool.

1 Radiator Draincock

2 Radiator Cap Cover

Change coolant according to engine

manual. Add coolant according to Sec-

tion 5-6).

Run engine until engine reaches normal

operating temperature. Check coolant

level in recovery tank. Add coolant if nec-

essary.

After engine cools, check coolant level

again and add coolant if necessary.

1

2

OM-4433 Page 34

8-6. Adjusting Engine Speed On Standard Models

803 563-E

3

1

2

RPM (Hz)

Engine Speed

(No Load)

Weld/Power 1880 (61.7)

Maximum

Stop engine and let cool.

Engine speed is factory set and

should not require adjustment. Af-

ter tuning engine, check engine

speed with tachometer or frequen-

cy meter. See table for proper no

load speed. If necessary, adjust

speed as follows:

Start engine and run until warm.

Turn Process/Contactor switch to

Weld Terminals Always On − Stick

position.

1 Lock Nut

2 Adjustment Screw

Loosen nut. Turn screw until engine

runs at weld/power speed. Tighten

nut.

Do not set engine speed higher

than specified. Tampering with

adjustments other than shown

may affect engine warranty

3 Engine Stop Lever

Stop engine.

Close door.

Tools Needed:

OM-4433 Page 35

8-7. Adjusting Engine Speed On Models With Automatic Idle (Optional)

803 563-G

1880 rpm max

(62.6 Hz)

1250 rpm

(41.6 Hz)

Engine Speed

(No Load)

1

2

3

4

To prevent solenoid

damage, be sure a 1/8

in (3 mm) gap exists be-

tween the engine low

speed screw and

throttle lever when the

solenoid is held in the

energized position.

Engine Speed Adjustment

After tuning engine, check en-

gine speed with tachometer or

frequency meter. See table for

proper no load speed. If neces-

sary, adjust speed as follows:

Start engine and run until warm.

Turn Process/Contactor switch

to Stick − Weld Terminals Al-

ways On position.

1 Throttle Rod / Plunger

2 Lock Nut

3 Rubber Boot

4 Adjustment Screw

Adjustment screw is not used to

adjust engine speed when auto-

matic idle option is installed.

However, it must be at least 1/8

in (3 mm) away from the throttle

arm when engine is running at

idle rpm.

Unhook rubber boot from the so-

lenoid housing but leave con-

nected to plunger.

Loosen lock nut. Place Engine

Control Switch in Auto position.

Turn throttle rod and plunger un-

til engine runs at idle speed.

Tighten lock nut.

Hook rubber boot back onto so-

lenoid housing.

Be sure solenoid plunger

pulls all the way in (“bot-

toms”) when energized.

Weld/Power Speed Adjust-

ment

Weld/power speed adjust-

ment must be done by the

engine manufacturer’s fac-

tory authorized service

agent.

Tampering with adjustments

other than shown may affect

engine warranty.

Stop engine.

OM-4433 Page 36

8-8. Servicing Fuel And Lubrication Systems

802 490 / Ref. 801 434

Stop engine and let cool.

After servicing, start engine

and check for fuel leaks.

Stop engine, tighten connec-

tions as necessary, and wipe

up spilled fuel.

1 Oil Filter

2 Oil Drain Valve And Hose

3 Oil Fill Cap

4 Primary (Canister) Fuel Filter

5 Secondary (In-Line) Fuel

Filter

6 Fuel Tank Sludge Drain Valve

To change oil and filter:

Route oil drain hose and valve

through hole in base. See engine

manual and engine maintenance

label for oil/filter change in-

formation.

To replace primary (canister) fuel

filter:

Turn filter counterclockwise. Re-

move filter.

Fill new filter with fresh fuel. Apply

thin coat of fuel to gasket on new fil-

ter. Install new filter and turn clock-

wise.

Inspect fuel lines, and replace if

cracked or worn.

To drain water from fuel system:

See engine manual.

To replace secondary (in-line)

fuel filter:

Note direction of fuel flow as indi-

cated by arrow on side of filter. Re-

move fuel line clamps and discon-

nect fuel lines from fuel filter. Re-

place filter, reconnect fuel lines, and

reinstall clamps.

To drain sludge from fuel tank:

Beware of fire. Do not smoke

and keep sparks and flames

away from drained fuel. Dis-

pose of drained fuel in an en-

vironmentally-safe manner.

Do not leave unit unattended

while draining fuel tank.

Properly lift unit and secure

in a level position. Use ade-

quate blocks or stands to

support unit while draining

fuel tank.

Attach 1/2 ID hose to drain valve.

Put metal container under drain,

and use screwdriver to open

sludge drain valve. Close valve

when sludge has drained. Remove

hose.

Close door.

Tools Needed:

6

3

5

2

4

1

OM-4433 Page 37

8-9. Overload Protection

803 562 / 803 566

1

5

Stop engine.

When a circuit breaker, supple-

mentary protector, or fuse

opens, it usually indicates a

more serious problem exists.

Contact Factory Authorized

Service Agent.

1 Fuse F1

F1 protects the stator exciter wind-

ing from overload. If F1 opens, weld

and generator power is low or stops

entirely.

2 Circuit Breaker CB1 (Not

Shown)

3 Supplementary Protector CB2

4 Supplementary Protector CB3

5 Supplementary Protector CB7

6 Supplementary Protector CB8

7 Circuit Breaker CB9

CB1 protects the engine battery cir-

cuit. If CB1 opens, the engine will not

crank. CB1 automatically resets

when the fault is corrected.

CB2 protects the engine wiring har-

ness. If CB2 opens, the engine will

not crank.

CB3 protects part of the weld control

wiring harness. If CB3 opens, weld

and generator power output stops.

CB7 protects the 115 volt ac output

to remote receptacle RC14. If CB7

opens, 115 volt output to RC14

stops.

CB8 protects the 24 volt ac output to

remote receptacle RC14. If CB8

opens, 24 volt output to RC14 stops.

Press button to reset supplementary

protector.

CB9 protects the throttle solenoid

against overload. If CB9 opens, the

engine does not automatically idle

down. Check the linkage and sole-

noid. CB9 automatically resets.

6

3

4

7

OM-4433 Page 38

8-10. Checking Generator Brushes

Ref 2114 778−D / S−0233−A

Stop engine and let cool.

1 Generator Brush With Spring

Mark and disconnect leads at brush hold-

er cap. Remove brushes.

Replace brushes if damaged or if brush

material is at or near minimum length.

1

5/16 in. (8 mm)

Minimum Length

9/16 in. (14.3 mm)

New Length

Replace

Damaged Brushes

Notes

16 Gauge (.063 in)

22 Gauge (.031 in)

24 Gauge (.025 in)

20 Gauge (.037 in)

18 Gauge (.050 in)

14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

MATERIAL THICKNESS REFERENCE CHART

OM-4433 Page 39

8-11. Voltmeter/Ammeter Help Displays

Use the Voltmeter/Ammeter help

displays to diagnose and correct

fault conditions.

When a help code is displayed

normally weld output has

stopped but generator power

output may be okay.

To reset help displays, stop

unit and then restart. See item

6 below to reset Help 25 dis-

play.

1 Help 20 Display

Indicates a failure of meter display

module PC2, or the wiring between

PC2 and main control module PC1.

If this display is shown, have Facto-

ry Authorized Service Agent check

PC1, PC2, and the wiring between

PC1 and PC2.

2 Help 21 Display

Indicates thermistor TH1 on the

main rectifier heat sink has failed.

If this display is shown, have Facto-

ry Authorized Service Agent check

TH1, and the wiring between TH1

and PC1.

3 Help 22 Display

Indicates the rectifier heat sink has

overheated. If this display is shown,

check generator cooling system

and/or reduce duty cycle. Keep en-

gine access door closed when run-

ning to maintain proper cooling air

flow past rectifier. Allow unit to cool

before restarting. If problem contin-

ues, have Factory Authorized Ser-

vice Agent check unit.

4 Help 23 Display

Indicates one of the rectifier output

SCR’s has failed. If this display is

shown, have Factory Authorized

Service Agent check the rectifier

SCR’s.

5 Help 24 Display

Indicates weld open circuit voltage

(OCV) is too high (above 41 volts

dc). If this display is shown, have

Factory Authorized Service Agent

check main control module PC1.

6 Help 25 Display

Indicates a remote device con-

nected to Remote Receptacle

RC14 may be faulty. Help 25 is also

displayed whenever a remote de-

vice has been connected to RC14

and then disconnected. Clear fault

by stopping and restarting the unit

or by turning Process/Contactor

switch to another position. If prob-

lem continues, have Factory Autho-

rized Service Agent check the re-

mote device, filter board PC6, and

main control module PC1.

2

1

HL.P 22

HL.P 23

HL.P 24

HL.P 25

HL.P 20

HL.P 21

6

5

4

3

803 562 / 217 357-A

OM-4433 Page 40

8-12. Troubleshooting

Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see

Section 8-11).

Note

A. Welding

Trouble Remedy

No weld output; generator power output

okay at ac receptacles. Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote

On/Off Switch Required position and turn remote contactor on (see Section 5-9).

Reset supplementary protector CB7 or CB8 (see Section 8-9). Check for faulty remote device connected

to RC14.

Check and secure connections to Remote Control receptacle RC14 (see Section 5-9).

Check Voltmeter/Ammeter help displays (see Section 8-11).

No weld output, or generator power out-

put at ac receptacles. Disconnect equipment from generator power receptacles during start-up.

Reset supplementary protector CB3. (see Section 8-9).

Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service

Agent check the voltage regulator module PC3.

Check Voltmeter/Ammeter help displays (see Section 8-11).

Have Factory Authorized Service Agent check brushes and slip rings, voltage regulator module PC3, and

field excitation circuit.

Erratic weld output. Check and tighten connections inside and outside unit.

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Have Factory Authorized Service Agent check brushes and slip rings.

High weld output. Have Factory Authorized Service Agent check main control module PC1 and hall device HD1.

Low weld output. Check engine speed, and adjust if necessary.

Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service

Agent check the rotor.

Low open-circuit voltage. Check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent check main control module PC1, voltage regulator module PC3,

and main rectifier.

No remote fine amperage control. Repair or replace remote control device.

Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 5-9).

No 24 volt or 115 volt ac output at Re-

mote receptacle RC14. Reset supplementary protector CB7 (24 volt) or CB8 (115 volt) (see Section 8-9).

OM-4433 Page 41

B. Generator Power

Trouble Remedy

No generator power output at ac recep-

tacles; weld output okay. Reset receptacle supplementary protector(s) (see Section 7-1).

No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.

Check fuse F1, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check vol-

tage regulator module PC3.

Reset supplementary protector CB3 (see Section 8-9).

Check Voltmeter/Ammeter help displays (see Section 8-11).

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

High output at generator power ac re-

ceptacles. Have Factory Authorized Service Agent check voltage regulator module PC3.

Low output at generator power ac recep-

tacles. Check engine speed, and adjust if necessary.

Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service

Agent check the rotor.

C. Engine

Trouble Remedy

Engine will not crank. Check battery, and replace if necessary.

Check battery connections and tighten if necessary.

Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-9).

Have Factory Authorized Service Agent check engine wiring harness and components.

Reset supplementary protector CB2 (see Section 8-9).

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check Engine Control switch S1, and control relay CR2.

Engine cranks but does not start. Check fuel level.

Check battery and replace if necessary. Check engine charging system according to engine manual.

Have Factory Authorized Service Agent check control relay CR1, fuel solenoid FS1, and the fuel

pump.

Air in fuel system. See engine manual.

Engine hard to start in cold weather. Use Preheat switch (see Section 6-1).

Keep battery in good condition. Store battery in warm area off cold surface.

Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for

fuel information.

Use correct grade oil for cold weather (see Section 8-2).

Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow

plug.

Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant

temperature is too high (see Section 5-6 ).

Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-9).

Reset supplementary protector CB2 (see Section 8-9). Have Factory Authorized Service Agent check

engine alternator, engine harness, throttle solenoid TS1, fuel solenoid FS1, and the fuel pump.

Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, inte-

grated rectifier SR2, fuel solenoid FS1, and the fuel pump.

See engine manual.

OM-4433 Page 42

Trouble Remedy

Engine slowly stopped and cannot be

restarted. Check fuel level.

Check engine air and fuel filters (see Sections 8-3 and 8-8).

See engine manual.

Battery discharges between uses. Turn Engine Control switch off when unit is not running.

Clean top of battery with baking soda and water solution; rinse with clear water.

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months).

Engine idles, but does not come up to

weld speed (units with idle option only). Have Factory Authorized Service Agent check idle module PC5 and current transformer CT1.

Check for obstructed throttle solenoid.

Engine does not run at idle speed

(units with idle option only). Check for obstructed throttle solenoid.

Circuit breaker CB9 may be open. CB9 automatically resets when fault is corrected (see Section 8-9).

Have Factory Authorized Service Agent check idle module PC5, and control relay CR4.

Engine uses oil during run-in period;

wetstacking occurs. Dry engine according to run-in procedure (see Section 10).

OM-4433 Page 43

Notes

16 Gauge (.063 in)

22 Gauge (.031 in)

24 Gauge (.025 in)

20 Gauge (.037 in)

18 Gauge (.050 in)

14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

MATERIAL THICKNESS REFERENCE CHART

OM-4433 Page 44

SECTION 9 − ELECTRICAL DIAGRAMS

Figure 9-1. Circuit Diagram For Welding Generator

OM-4433 Page 45

219 228−D

OM-4433 Page 46

SECTION 10 − RUN-IN PROCEDURE

run_in1 8/01

10-1. Wetstacking

Do not perform run-in

procedure at less than 20

volts weld output and do not

exceed duty cycle or equip-

ment damage may occur.

1 Welding Generator

Run diesel engines near rated volt-

age and current during run-in period

to properly seat piston rings and

prevent wetstacking. See name-

plate, rating label, or specifications

section in this manual to find rated

voltage and current.

 Do not idle engine longer than

necessary. Piston rings seat

faster if engine runs at weld/

power rpm, and the welding

generator is kept loaded during

run-in.

2 Engine Exhaust Pipe

Wetstacking is unburned fuel and

oil in the exhaust pipe and occurs

during run-in if the engine is run too

long at light load or idle rpm.

If exhaust pipe is coated with a wet,

black, tar-like substance, dry the

engine using one of the following

run-in procedures.

See the engine manual for addition-

al engine run-in information.

2

1

OM-4433 Page 47

10-2. Run-In Procedure Using Load Bank

S-0683

Stop engine.

Do not touch hot exhaust

pipe, engine parts, or load

bank/grid.

Keep exhaust and pipe away

from flammables.

Do not perform run-in

procedure at less than 20

volts weld output and do not

exceed duty cycle or equip-

ment damage may occur.

1 Load Bank

Turn all load bank switches Off. If

needed, connect load bank to 115

volts ac wall receptacle or genera-

tor auxiliary power receptacle.

2 Welding Generator

Place V/A control in minimum posi-

tion, and Output Selector switch (if

present) in either DC position.

3 Weld Cables

Connect load bank to generator

weld output terminals using proper

size weld cables with correct

connectors. Observe correct

polarity.

Start engine and run for several

minutes.

Set load bank switches and then

adjust generator A/V control so load

equals rated voltage and current of

generator (see nameplate, rating

label, or the specifications section

in this manual).

Check generator and load bank

meters after first five minutes then

every fifteen minutes to be sure

generator is loaded properly.

Check oil level frequently dur-

ing run-in; add oil if needed.

After one hour (minimum) place A/V

control in minimum position, then

turn off load bank to remove load.

Run engine several minutes at no

load.

Stop engine and let cool.

4 Engine Exhaust Pipe

Repeat procedure if wetstacking is

present.

2

3

1

4

OM-4433 Page 48

10-3. Run-In Procedure Using Resistance Grid

S-0684

Stop engine.

Do not touch hot exhaust

pipe, engine parts, or load

bank/grid.

Keep exhaust and pipe away

from flammables.

Do not perform run-in

procedure at less than 20

volts weld output and do not

exceed duty cycle or equip-

ment damage may occur.

1 Resistance Grid

Use grid sized for generator rated

output.

Turn Off grid.

2 Welding Generator

Place V/A control in minimum posi-

tion, and Output Selector switch (if

present) in either DC position.

3 Weld Cables

Connect grid to generator weld

output terminals using proper size

weld cables with correct connec-

tors (polarity is not important).

4 Voltmeter

5 Clamp-On Ammeter

Connect voltmeter and ammeter as

shown, if not provided on generator.

Start engine and run for several

minutes.

Set grid switches and then adjust

generator A/V control so load

equals rated voltage and current of

the generator (see nameplate, rat-

ing label, or the specifications sec-

tion in this manual).

Check generator and meters after

first five minutes then every fifteen

minutes to be sure generator is

loaded properly.

Check oil level frequently dur-

ing run-in; add oil if needed.

After one hour (minimum), place

A/V control in minimum position,

then shut down grid to remove load.

Run engine several minutes at no

load.

Stop engine and let cool.

6 Engine Exhaust Pipe

Repeat procedure if wetstacking is

present.

1

35

+

4

2

6

OM-4433 Page 49

SECTION 11 − GENERATOR POWER GUIDELINES

The views in this section are intended to be representative of all engine-driven

welding generators. Your unit may differ from those shown.

NOTE

11-1. Selecting Equipment

gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

Do not use 2-prong plug un-

less equipment is double in-

sulated.

OR

2

Be sure equipment

has this symbol

and/or wording.

3

1

11-2. Grounding Generator To Truck Or Trailer Frame

S-0854

Always ground generator

frame to vehicle frame to pre-

vent electric shock and static

electricity hazards.

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied)

3 Metal Vehicle Frame

Connect cable from equipment

ground terminal to metal vehicle

frame. Use #10 AWG or larger

insulated copper wire.

If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

Electrically bond generator

frame to vehicle frame by

metal-to-metal contact.

GND/PE

3

1

2

Bed liners, shipping skids, and some running

gear insulate the welding generator from the ve-

hicle frame. Always connect a ground wire from

the generator equipment grounding terminal to

bare metal on the vehicle frame as shown.

OM-4433 Page 50

11-3. Grounding When Supplying Building Systems

ST-800 576-B

1 Equipment Grounding

Terminal

2 Grounding Cable

Use #10 AWG or larger insulated

copper wire.

3 Ground Device

Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

GND/PE

1 2

Use ground device as stated

in electrical codes.

23

11-4. How Much Power Does Equipment Require?

S-0623

1 Resistive Load

A light bulb is a resistive load and

requires a constant amount of power.

2 Non-Resistive Load

Equipment with a motor is a non-re-

sistive load and requires approxi-

mately six times more power while

starting the motor than when running

(see Section 11-8).

3 Rating Data

Rating shows volts and amperes, or

watts required to run equipment.

VOLTS 115

4.5

60

AMPS

Hz

1

2

3

3

EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power

requirement in watts.

4.5 A x 115 V = 520 W

The load applied by the drill is 520 watts.

EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,

add the individual loads to calculate total load.

The total load applied by the three flood lamps and drill is 1120 watts.

(200 W + 200 W + 200 W) + 520 W = 1120 W

AMPERES x VOLTS = WATTS

OM-4433 Page 51

11-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

1/6 HP 1225 500

1/4 HP 1600 600

1/3 HP 2100 700

1/2 HP 3175 875

Capacitor Start-Induction Run 1/3 HP 2020 720

1/2 HP 3075 975

3/4 HP 4500 1400

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850

3 HP 15900 3900

5 HP 23300 6800

Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

1/6 HP 1400 550

1/4 HP 1850 650

1/3 HP 2400 800

1/2 HP 3500 1100

11-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000

Grain Cleaner 1/4 HP 1650 650

Portable Conveyor 1/2 HP 3400 1000

Grain Elevator 3/4 HP 4400 1400

Milk Cooler 2900 1100

Milker (Vacuum Pump) 2 HP 10500 2800

FARM DUTY MOTORS 1/3 HP 1720 720

Std. (e.g. Conveyors, 1/2 HP 2575 975

Feed Augers, Air 3/4 HP 4500 1400

Compressors) 1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850

3 HP 15900 3900

5 HP 23300 6800

High Torque (e.g. Barn 1-1/2 HP 8100 2000

Cleaners, Silo Unloaders, 5 HP 23300 6000

Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000

10 HP 46700 10700

3-1/2 cu. ft. Mixer 1/2 HP 3300 1000

High Pressure 1.8 Gal/Min 500 PSI 3150 950

Washer 2 gal/min 550 PSI 4500 1400

2 gal/min 700 PSI 6100 1600

Refrigerator or Freezer 3100 800

Shallow Well Pump 1/3 HP 2150 750

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

OM-4433 Page 52

11-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

3/8 in 400 400

1/2 in 600 600

Circular Saw 6-1/2 in 500 500

7-1/4 in 900 900

8-1/4 in 1400 1400

Table Saw 9 in 4500 1500

10 in 6300 1800

Band Saw 14 in 2500 1100

Bench Grinder 6 in 1720 720

8 in 3900 1400

10 in 5200 1600

Air Compressor 1/2 HP 3000 1000

1 HP 6000 1500

1-1/2 HP 8200 2200

2 HP 10500 2800

Electric Chain Saw 1-1/2 HP, 12 in 1100 1100

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

Heavy Duty 12 in 500 500

Electric Cultivator 1/3 HP 2100 700

Elec. Hedge Trimmer 18 in 400 400

Flood Lights HID 125 100

Metal Halide 313 250

Mercury 1000

Sodium 1400

Vapor 1250 1000

Submersible Pump 400 gph 600 200

Centrifugal Pump 900 gph 900 500

Floor Polisher 3/4 HP, 16 in 4500 1400

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

1 HP 6100 1600

55 gal Drum Mixer 1/4 HP 1900 700

Wet & Dry Vac 1.7 HP 900 900

2-1/2 HP 1300 1300

OM-4433 Page 53

11-8. Power Required To Start Motor

S-0624

1 Motor Start Code

2 Running Amperage

3 Motor HP

4 Motor Voltage

To find starting amperage:

Step 1: Find code and use table to

find kVA/HP. If code is not listed,

multiply running amperage by six to

find starting amperage.

Step 2: Find Motor HP and Volts.

Step 3: Determine starting amper-

age (see example).

Welding generator amperage out-

put must be at least twice the

motor’s running amperage.

VOLTS AMPS

HP

230 2.5

1/4

Hz

PHASE

CODE 60

1

M

AC MOTOR

12

3

4

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GH J K LMNP

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4

HP motor with a motor start code of M.

Starting the motor requires 12.2 amperes.

11.2 x 1/4 x 1000

230 = 12.2 A

kVA/HP x HP x 1000

VOLTS = STARTING AMPERAGE

Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2

11-9. How Much Power Can Generator Supply?

Ref. ST-800 396-A / S-0625

1 Limit Load To 90% Of

Generator Output

Always start non-resistive (motor)

loads in order from largest to small-

est, and add resistive loads last.

2 5 Second Rule

If motor does not start within 5

seconds, turn off power to prevent

motor damage. Motor requires

more power than generator can

supply.

1

2

OM-4433 Page 54

11-10. Typical Connections To Supply Standby Power

Have only qualified persons perform

these connections according to all

applicable codes and safety practic-

es.

Properly install and ground this

equipment according to its Owner’s

Manual and national, state, and local

codes.

Customer-supplied equipment is re-

quired if generator will supply standby

power during emergencies or power out-

ages.

1 Utility Electrical Service

2 Transfer Switch (Double-Throw)

Switch transfers the electrical load from

electric utility service to the generator. Trans-

fer load back to electric utility when service is

restored.

Install correct switch (customer-supplied).

Switch rating must be same as or greater

than the branch overcurrent protection.

3 Fused Disconnect Switch

Install correct switch (customer-supplied) if

required by electrical code.

4 Welding Generator Output

Generator output voltage and wiring must be

consistent with regular (utility) system volt-

age and wiring.

Connect generator with temporary or perma-

nent wiring suitable for the installation.

Turn off or unplug all equipment connected to

generator before starting or stopping engine.

When starting or stopping, the engine has

low speed which causes low voltage and

frequency.

5 Essential Loads

Generator output may not meet the electrical

requirements of the premises. If generator

does not produce enough output to meet all

requirements, connect only essential loads

(pumps, freezers, heaters, etc. − See Sec-

tion 11-4).

Properly install and ground this equipment according to

its Owner’s Manual and national, state, and local codes.

Transfer Switch

Essential

Loads

Fused

Disconnect

Switch

(If Required)

Utility

Electrical

Service

1234

5

Welding

Generator

Output

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4433 Page 55

11-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads

 If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current

(Amperes) Load (Watts) 4 6 8 10 12 14

5 600 350 (106) 225 (68) 137 (42) 100 (30)

7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)

10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)

15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)

20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)

25 3000 175 (53) 112 (34) 62 (19) 37 (11)

30 3600 150 (46) 87 (26) 50 (15) 37 (11)

35 4200 125 (38) 75 (23) 50 (15)

40 4800 112 (34) 62 (19) 37 (11)

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

 If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current

(Amperes) Load (Watts) 4 6 8 10 12 14

5 1200 700 (213) 450 (137) 225 (84) 200 (61)

7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)

10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)

15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)

20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)

25 6000 350 (107) 225 (69) 125 (38) 75 (23)

30 7000 300 (91) 175 (53) 100 (31) 75 (23)

35 8400 250 (76) 150 (46) 100 (31)

40 9600 225 (69) 125 (38) 75 (23)

45 10,800 200 (61) 125 (38)

50 12,000 175 (53) 100 (31)

*Conductor size is based on maximum 2% voltage drop

OM-4433 Page 56

SECTION 12 − PARTS LIST

Hardware is common and not

available unless listed.

Wirng harnesses are listed at

the end of parts section.

1 (Fig.12-3)

2

3

4

5

6 (Fig.12-5)

7

89

10

11

12

13

14 16

17 18 19 20

21

22

23

15

24 25 26

27

28

90

91

92

93

94

95

96

9897

99

100

101

102

103

104

105

106

107

108 (Fig.12-2)

109

Figure 12-1. Main Assembly

OM-4433 Page 57

803 683-B

29

30

31

32

33 34

35

36 37

38

39

40

41

42

43

44

45

46

47

48

49 50 51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

69

68

70

71

74

72

73

75

76

77

78

79

80

81 (Fig. 12-4)

82

83

84

85

86

87

88

89

OM-4433 Page 58

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 12-1. Main Assembly

Quantity

1 Figure 12−3 Control Panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 213504 Tray, Reactor & Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213491 Insulator, Capacitor Bank (Applies To Reactor/Rectifier Tray) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 HD1 168829 Transducer, Current 1000a Module Max Open Loop 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 R3 213027 Resistor, WW Tap 300 W 40 Ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 217070 Bracket, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Figure 12−5 Rectifier Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 214742 Capacitor Assy (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213489 Bus Bar, Capacitor Bank Negative 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213490 Bus Bar, Capacitor Bank Positive 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C10 163535 Capacitor, Elctlt 16000 Uf 60 Vdc Can 1.75 Dia 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181853 Insulator, Screw (For Rectifier Mtg) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 +213488 Panel, Engine Side 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PC1 228727 Module, Main Control/Scr Gating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 PC3 214770 Module, Voltage Regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 215522 Bracket, Vault 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Z1 213929 Stabilizer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192303 Angle, Mtg Stabilizer 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 TE1 172661 Block, Stud Connection 6 Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173734 Link, Jumper 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 213500 Brkt, Beam Support 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 213602 Gasket, Exhaust Outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 214753 Bracket, Holddown Fuel Tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213506 Bracket, Hold−Down Fuel Tank (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 213493 Upright, Center Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 189464 Seal, Weather Lift Eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 213501 Bracket, Fuel Pump/Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 Bracket, Fuel Filter Mtg. (Order Thru Engine Manufacturer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 217687 Filter, Fuel Spin−on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 207721 Pump, Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 *213858 Filter, Fuel In−line 5/16x5/16 Mic 125 −175 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 212621 Pipe, Exhaust Flexible Inlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 183314 Clamp, Muffler 1.625 Dia U Pld 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 212604 Baffle, Air Lower Radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 201528 Muffler, Exhaust Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 212605 Pipe, Exhaust Blue Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 +213470 Cover, Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049525 Nut, 312−18 U−nut Multi−thread 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 189052 Grommet, Plastic Neck Filler Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 190198 Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 222513 Label, Warning Falling Equipment Can Cause Serious 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 201851 Cover, Radiator Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 214604 Pipe, Exhaust Elbow 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 224265 Label, Warning Hot Exhaust Parts Do Not Touch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 192041 Label, Use Diesel Fuel Only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 213472 Keeper, Latch Engine Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 213471 Bracket, Cover Top 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 217387 Baffle, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 213503 Guard, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 +212607 Shroud, Radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 212606 Radiator, W/14# Cap 3 Row Core 1.25 In Inlet/Outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 212603 Baffle, Air Upper Radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 +220954 Upright, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 224265 Label, Warning Hot Exhaust Parts Do Not Touch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4433 Page 59

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 12-1. Main Assembly (Continued)

Quantity

46 220295 Bracket, Stiffener 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 190190 Tank, Coolant Recovery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 213502 Guard, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 218303 Label, Diesel Engine Maintenance Perkins 403C−15 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 199592 Latch, Paddle Series 20 (Black) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 +213487 Door, Engine Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191626 Bumper, Door Engine Access 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 225120 Label, Warning Moving Parts Can Cause Injury 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 189975 Hinge, Door Access 180 Deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 087341 Bumper, Door 1.000 Od X .750 High Rbr 50 Duro W/O 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 213486 Panel, Rocker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 217698 Label, Help Codes 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 168385 Label, Warning Battery Explosion Can Blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 203260 Label, Caution Do Not Use Ether 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 225120 Label, Warning Moving Parts Can Cause Injury 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦230637 Idle, Solenoid Assy (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 ♦230828 Bracket, Mtg Solenoid Idle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 TS1 ♦230634 Solenoid, Throttle W/4−8.4 Lb Spring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦198109 Screw, Shld Stl Sch .250−20 X .437 X .500 Shld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 ♦198018 Linkage, Throttle Solenoid 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦230830 Arm, Throttle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 213266 Mount, Engine/Generator Flange Mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 197506 Screw, M14−1.5x 30 Hex Hd−pln 8.8 Pln 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 213480 Bracket, Mtg Engine 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 083883 Washer, Lock .402idx0.709odx.087t Stl Split10mm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 049026 Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 Washer, Oil Drain (Order Thru Engine Manufacturer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 212612 Ftg, Adapter Oil Drain 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199505 Hose Assy, Oil Drain 32.000 Lg (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 165271 Valve, Oil Drain 3/8−18 Nptf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 176529 Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 113854 Hose, Sae .500 Id X .780 Od Xcoil 2.6 Ft.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 197448 Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 3/8 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 212614 Hose, Radiator Lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 217686 Belt, Alternator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 217651 Engine, Perkins (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212600 Flywheel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*202166 Filter, Oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217695 Switch, Coolant Temp N.c. 110c 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217696 Switch, Lubricating Oil Pressure N.O. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 212613 Hose, Radiator Upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 216811 Clip, Nut Retaining 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 197613 Air Cleaner, Intake 5.250 In (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197675 Dust Ejector, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*197676 Element, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197677 Cover Assy, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197678 Body, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦*197679 Element, Air Cleaner Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197829 Bracket, Mtg Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 212617 Hose, Air Intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 Figure 12−4 Generator Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 213461 Bracket, Mtg Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4433 Page 60

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 12-1. Main Assembly (Continued)

Quantity

83 213266 Mount, Engine/Generator Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212623 Tank, Fuel (Includes Fuel Cap And Items Below) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 189908 Valve, Drain Fuel 180 Deg Zinc Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 181572 Bushing, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 124253 Bushing, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 212611 Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 212610 Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 SENDER 213265 Sender, Fuel Gauge 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172071 Clamp, Hose .520 − .605 Clp Dia Slfttng Black 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211961 Hose, Sae .312 Id X .560 Od X 16.000 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213804 Hose, Sae .312 Id X .560 Od X 2.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191819 Hose, Sae .312 Id X .560 Od X 15.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145054 Hose, Sae .187 Id X .410 Od X 26.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 213465 Bolt, J Stl .312−18 X 7.250 Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91 213466 Bracket, Battery Holddown 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 BATT 146237 Battery, Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 190207 Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 213668 Bracket, Mtg Unit 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 213458 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96 213483 Support, Engine Rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 190206 Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98 224266 Label, Warning Do Not Weld On Base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 213462 Pad, Mtg Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213670 Screw, 500−13x2.25 Hex Flange−hd Gr8 Pln Chem/Phys 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

071731 Washer, Flat .656idx2.250odx.187t Stl Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 213463 Spacer/Snubber, Generator Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213600 Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

071731 Washer, Flat .656idx2.250odx.187t Stl Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213464 Bracket, Battery Locator (In Base − Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 213485 Support, Engine Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 213459 Crossmember, Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 213460 Crossmember, Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 +220953 Upright, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105 223379 Label, Warning General Precautionary CSA 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106 216347 Label, Rating Card Code 151 (Provide Serial No. When Ordering) 1. . . . . . . . . . . . . . . . . . . . . .

107 220955 Panel, Front Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108 Figure 12−2 Front Panel Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109 ♦105370 Xfmr, Current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218306 Kit, Label (Includes Safety & Informational Labels) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

* Recommended Spare Parts.

♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4433 Page 61

Hardware is common and not

available unless listed.

Wirng harnesses are listed at

the end of parts section.

803 684-B

123

4

5

6

37

36

7

89

10 11

12

13 14

15

16

17

18

19

31

32

33

34

35

20

21

22

23 24

25

26 27

28

29

30

24

Figure 12-2. Panel, Front w/Components

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 108)

Quantity

1 097926 Knob, Pointer 2.375 Dia X .250 Id W/Set Screwsplstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 072590 Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 170391 Conn, Circ Ms Protective Cap Size 20 Nylon 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 190323 Boot, Circuit Breaker Clear Hex Nut 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 097922 Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Nameplate, Control (Order By Model & Serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PC6 217008 Circuit Card Assy, Connector/Receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CB7, CB8 083432 Supplementary Pro, Man Reset 1p 10a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . .

9 213655 Panel, Front Engine/Weld Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4433 Page 62

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 12-2. Panel, Front w/Components (Continued)

Quantity

10 214543 Enclosure, Circuit Card Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 134201 Stand−off Support, Pc Card .312/.375w/Post&lock .43 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 PC2 214660 Circuit Card Assy, Display W/Program 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 R1 214760 Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 R2 193118 Pot, Cp Flat 1t 2. W 1k Ohm Linear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 S4 021467 Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 S1 212436 Switch, Ignition 4 Position (Includes Knob) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 039047 Terminal, Pwr Output Red 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 010381 Connector, Rectifier 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 C13, 14, 15 128750 Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 209056 Cover, Receptacle W/Gasket 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 RC11 182954 Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 Nameplate, Generator Power (Order By Model & Serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 213509 Panel, Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 RC5,6 214918 Rcpt,Str Dx Grd 2p3w 20a 125v *5−20r (Order By Model & Serial No.). . . . . . . . . . .

24 GFCI1, 2 151981 Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi (Order By Model & Serial No.). . . . . . . . .

25 C11, C12 217054 Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 CB4, CB6 093996 Supplementary Pro, Man Reset 1p 20a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . .

27 CB5 203026 Supplementary Protector, Man Reset 2p 50a 240vac 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 GRD 083030 Stud, Brs .250−20 X 1.750 W/Hex Collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 010915 Washer, Flat .257idx0.640odx.031t Brs 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 601836 Nut, 250−20 .50hex .19h Brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 Nameplate, Weld Terminal (Order By Model & Serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 181169 Spacer, Output Stud 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 186621 Boot, Generic Output Stud 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 180735 Washer, Output Stud 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 039046 Terminal, Pwr Output Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 FUEL/HM 214768 Gauge, Fuel Elec/Hour Meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 021385 Boot, Toggle Switch Lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4433 Page 63

Hardware is common and not

available unless listed.

Wirng harnesses are listed at

the end of parts section.

803 689-D

1

2

3

4

5

6

7

8

9

10

13

12

11

14

15

Figure 12-3. Control Panel

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 12-3. Control Panel (Figure 12-1 Item 1)

Quantity

1 220981 Bracket, Mtg Components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 129524 Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CR2 214876 Relay, Encl 6vdc Spst 35a/14vdc 5 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 CB1 190374 Circuit Breaker, Auto Reset 12vdc 40 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 CR1 223710 Relay, Encl 12vdc Dpst−no 25a 6pin Flange 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 046432 Holder, Fuse Mintr .250 X 1.250 Panel Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 F1 085874 Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 R4 217335 Resistor Board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 CR4 ♦090104 Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CR3 197325 Relay, Encl 12vdc Spst 70a 4pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 SR3 ♦035704 Rectifier, Integ Bridge 40. Amp 800v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 SR1, SR2 035704 Rectifier, Integ Bridge 40. Amp 800v 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 PC5 ♦214761 Module, Pull To Idle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CB2, CB3 083432 Supplementary Pro, Man Reset 1p 10a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . .

15 CB9 ♦230635 Circuit Breaker, Auto Reset 12vdc 8 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4433 Page 64

803 686-A

Hardware is common and not

available unless listed.

Wirng harnesses are listed at

the end of parts section.

2

3

1

4

5

6

7

8

9

10

11

12

13

14

19

20 18

15

17 16

Figure 12-4. Generator

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 12-4. Generator (Figure 12-1 Item 81)

Quantity

1 ROTOR 212474 Rotor, Generator 4 Pole (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 053390 Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 192600 Fan, Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 159918 Baffle, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 212126 Adapter, Engine Machined 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 602211 Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 192686 Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 602211 Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 192686 Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 212641 Stud, Stl .375−16 1.625x 19.000 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 STATOR 212470 Stator, Generator 4 Pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 160943 Endbell 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 167788 Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 218552 Brush, Assembly 2 Pole (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 047879 Bar, Retaining Brushholder 2 Brushes 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 161306 Cap, Brushholder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 126984 Brush w/Spring 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 005614 Holder, Brush 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 125548 Holder, Brush Elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 158832 Screw, 010−32x .50 Hex Hd−slt Stl Pld Sq Cone Sems 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

*Recommended Spare Parts.

♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4433 Page 65

803 685-A

Hardware is common and not

available unless listed.

Wirng harnesses are listed at

the end of parts section.

1

2

3

6

4

5

9

8

10

7

Figure 12-5. Rectifier Assembly

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 12-5. Rectifier Assembly (Figure 12-1 Item 6)

Quantity

217081 Rectifier, Assembly (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 211984 Heat Sink 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 MOD1,2,3 218296 Kit, Module SCR 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 MOD4,5,6 218292 Kit, Module SCR 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 212602 Bus Bar, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 212639 Bus Bar, Rectifier 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 212601 Insulator, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 TH1 213930 Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8C1−6 215611 Capacitor Assy 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 C7,8,9 048420 Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 217085 Bus Bar, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181853 Insulator, Screw (For Mounting Rectifier) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4433 Page 66

Some wiring harness components (switches, relays, supplementary protectors) are also

referenced elsewhere in this parts list. Purchase components separately or as part of the

associated wiring harness.

Note

Description

Part

No.

Dia.

Mkgs.

Item

No.

Wiring Harnesses

Quantity

231122 Harness, Engine (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S4 021467 Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SR1, SR2 035704 Rectifier, Integ Bridge 40. Amp 800v 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB1 190374 Circuit Breaker, Auto Reset 12vdc 40 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB2, CB3 083432 Supplementary Pro, Man Reset 1p 10a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR3 197325 Relay, Encl 12vdc Spst 70a 4pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR2 214876 Relay, Encl 6vdc Spst 35a/14vdc 5 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R4 217335 Resistor Board, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148850 Socket, Relay 5 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212116 Conn, Deutsch 2p 1row Female Plug 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212117 Conn, Deutsch Wedge Lock 2 Position 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 214932 Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214933 Seal, Wire Univ 039 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214934 Seal, Plug Univ 039 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For S1 211292 Conn, Pack 4p 1row Female 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For S1 211293 Conn, Pack Terminal Position Assurance(Lock) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

129524 Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217002 Harness, Weld Control (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG2 150316 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG9 214951 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214933 Seal, Wire Univ 039 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214934 Seal, Plug Univ 039 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8 147992 Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 193184 Conn, Rect Cinch 30 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG7 193183 Conn, Rect Cinch 18 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG9 215261 Conn, Deutsch 12p 2row Female Plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 215262 Conn, Deutsch 12p 2row Female Plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215265 Conn, Deutsch Wedge Lock 12 Position 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215343 Seal, Plug Deutsch 12−16 Size 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG5 113750 Conn, Rect Mini 045 4skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217000 Cable, Lem 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215340 Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214933 Seal, Wire Univ 039 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214984 Harness, Rectifier Cc/Cv (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG11 193183 Conn, Rect Cinch 18 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

207716 Conn, Faston Mini Polarized 2 Skt G1k1 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

207718 Conn, Faston Mini Polarized 2 Skt G2k2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217010 Harness, Receptacle Auxiliary Power (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB4, CB6 093996 Supplementary Pro, Man Reset 1p 20a 250vac Fric 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Questions?

Call

1-800-4-A-MILLER

for your local

Miller distributor.

miller_warr 2006−01

Your distributor also gives

you ...

Service

You always get the fast,

reliable response you

need. Most replacement

parts can be in your

hands in 24 hours.

Support

Need fast answers to the

tough welding questions?

Contact your distributor.

The expertise of the

distributor and Miller is

there to help you, every

step of the way.

Effective January 1, 2006

(Equipment with a serial number preface of “LG” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

LIMITED WARRANTY − Subject to the terms and conditions

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to

its original retail purchaser that new Miller equipment sold after

the effective date of this limited warranty is free of defects in

material and workmanship at the time it is shipped by Miller. THIS

WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or

replace any warranted parts or components that fail due to such

defects in material or workmanship. Miller must be notified in

writing within thirty (30) days of such defect or failure, at which

time Miller will provide instructions on the warranty claim

procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed

below in the event of such a failure within the warranty time

periods. All warranty time periods start on the date that the

equipment was delivered to the original retail purchaser, or one

year after the equipment is sent to a North American distributor

or eighteen months after the equipment is sent to an

International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Process Controllers

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Sources (Unless Otherwise Stated)

* Water Coolant Systems (Integrated)

* Intellitig

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the

engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

* Positioners and Controllers

* Automatic Motion Devices

* RFCS Foot Controls

* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders

* Water Coolant Systems (Non-Integrated)

* Flowgauge and Flowmeter Regulators (No Labor)

* HF Units

* Grids

* Spot Welders

* Load Banks

* Arc Stud Power Sources & Arc Stud Guns

* Racks

* Running Gear/Trailers

* Plasma Cutting Torches (except APT & SAF

Models)

* Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)

* Bernard-Branded Mig Guns (No Labor)

* Weldcraft-Branded TIG Torches (No Labor)

* Subarc Wire Drive Assemblies

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches and Subarc (SAW) Guns

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls

* APT & SAF Model Plasma Cutting Torches

* Remote Controls

* Accessory (Kits)

* Replacement Parts (No labor)

* Spoolmate Spoolguns

* Canvas Covers

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays

or parts that fail due to normal wear. (Exception:

brushes, slip rings, and relays are covered on Bobcat,

Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such

as engines or trade accessories. These items are covered

by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed,

improperly operated or misused based upon industry

standards, or equipment which has not had reasonable and

necessary maintenance, or equipment which has been

used for operation outside of the specifications for the

equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND

USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS

TRAINED AND EXPERIENCED IN THE USE AND

MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the

exclusive remedies shall be, at Miller’s option: (1) repair; or (2)

replacement; or, where authorized in writing by Miller in

appropriate cases, (3) the reasonable cost of repair or

replacement at an authorized Miller service station; or (4)

payment of or credit for the purchase price (less reasonable

depreciation based upon actual use) upon return of the goods at

customer’s risk and expense. Miller’s option of repair or

replacement will be F.O.B., Factory at Appleton, Wisconsin, or

F.O.B. at a Miller authorized service facility as determined by

Miller. Therefore no compensation or reimbursement for

transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY

OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION

OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,

INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED

BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an

implied warranty lasts, or the exclusion of incidental, indirect,

special or consequential damages, so the above limitation or

exclusion may not apply to you. This warranty provides specific

legal rights, and other rights may be available, but may vary from

state to state.

In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,

and to the extent that they may not be waived, the limitations and

exclusions set out above may not apply. This Limited Warranty

provides specific legal rights, and other rights may be available,

but may vary from province to province.

PRINTED IN USA © 2006 Miller Electric Mfg. Co.2006−01

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

www.MillerWelds.com

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier to:

For Service

Owner’s Record

File a claim for loss or damage during

shipment.

For assistance in filing or settling claims, contact

your distributor and/or equipment manufacturer’s

Transportation Department.

Contact your Distributor for:

To locate a Distributor or Service Agency visit

www.millerwelds.com or call 1-800-4-A-Miller