Miller Electric Big Blue 402P Users Manual O491ap_mil

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Big Blue 402P, 502P, 602P



OM-491 190 355AP

October 2003

Visit our website at

www.MillerWelds.com

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

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 catalog 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 7/03

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. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Information sur les champs électromagnétiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3-1. Symbols And Definitions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Weld, Power, And Engine Specifications 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Dimensions, Weights, And Operating Angles 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Volt-Ampere Curves For CC Models 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Volt-Ampere Curves For CC/CV Models 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Fuel Consumption 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Duty Cycle And Overheating 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. AC Generator Power Curve 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Optional Three-Phase Generator Curves 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Mounting Welding Generator 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Using Lifting Eye 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Installing Exhaust Pipe 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Activating The Dry Charge Battery (If Applicable) 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Connecting The Battery 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Engine Prestart Checks 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Connecting To Weld Output Terminals 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Selecting Weld Cable Sizes* 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 22 . . . . . . . . . . . . . . . . . . . . .

5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Front Panel Controls For CC Models (See Section 6-2) 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) 24 . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Remote Amperage Control On CC Models (Optional) 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Weld Control/Arc Condition Information Label 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 28 . . . . . . . . . . . . . . . . . . . . . .

7-3. Process/Contactor Switch On CC/CV Models 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 8 − OPERATING AUXILIARY EQUIPMENT 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. 120 Volt And 240 Volt Receptacles 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) 32 . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Optional Generator Power Receptacles 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − MAINTENANCE & TROUBLESHOOTING 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Routine Maintenance 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Maintenance Label 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Servicing Air Cleaner 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-5. Adjusting Engine Speed 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-6. Servicing Fuel And Lubrication Systems 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-7. Overload Protection 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-8. Diagnosing Causes Of Engine Fault Shutdowns 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-9. Troubleshooting 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − ELECTRICAL DIAGRAMS 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − RUN-IN PROCEDURE 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. Wetstacking 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-2. Run-In Procedure Using Load Bank 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-3. Run-In Procedure Using Resistance Grid 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − GENERATOR POWER GUIDELINES 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − PARTS LIST 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES

WARRANTY

OM-491 Page 1

Return To Table Of Contents

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom _nd_8/03

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.

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 exhaust at the arc to remove welding

fumes and gases.

If ventilation is poor, use an approved air-supplied respirator.

Read 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 if necessary, 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 a welding helmet fitted with a proper shade of filter 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 and glare;

warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant material (wool

and leather) and foot protection.

OM-491 Page 2 Return To Table Of Contents

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.

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

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

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

possible, tightly cover them with approved covers.

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 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.

Allow cooling period before maintaining.

Wear protective gloves and clothing when working on

a hot engine.

Do not touch hot engine parts or just-welded parts

bare-handed.

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, 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.

Read and follow instructions on compressed gas cylinders, associated

equipment, and 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 guards or covers 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 panels or guards and close doors 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.

OM-491 Page 3

Return To Table Of Contents

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.

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

FALLING UNIT can cause injury.

Use lifting eye to lift unit only, NOT running gear, gas

cylinders, trailer, or any other accessories.

Use equipment of adequate capacity to lift and

support unit.

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-491 Page 4 Return To Table Of Contents

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 American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

(phone: 305-443-9353, website: www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-

ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).

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 and www. sparky.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 first. If cleared by your doctor,

then following the above procedures is recommended.

OM-491 Page 5

Revenez à la table des matières

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_fre 8/03

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 si-

gnifie Mise en garde !

Soyez vigilant ! Il y a des

risques de danger reliés

aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux

PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-des-

sous afin de connaître les mesures 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 ris-

ques de danger. Lorsque vous voyez un symbole, soyez

vigilant et suivez les directives mentionnées afin d’éviter tout

danger. Les consignes de sécurité présentées ci-après ne font

que résumer l’information contenue dans les normes de sécu-

rité énumérées à la section 2-6 . 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

particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut

provoquer 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 àcourant électrique dans les zones

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

Se servir d’une source électrique àcourant électrique UNIQUEMENT si le

procédé de soudage le demande.

Si l’utilisation d’une source électrique àcourant électrique s’avère néces-

saire, 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

échafaudages; 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 ma-

nuel AC avec tension à vide réduite. Dans la plupart des cas, un poste

courant continu de type CV est recommandé. 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 en-

dommagé 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.

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

comme indiqué dans la Section Maintenance avant de toucher des compo-

sants.

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’interieur, ventiler la zone et/ou utiliser un échappement au niveau de

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

Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air

homologué.

Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-

tions du fabricant concernant les métaux, les consommables, les

revêtements, les nettoyants et les dégraisseurs.

Travailler dans un espace fermé seulement s’il est bien ventilé ou en por-

tant 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 déplacer 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 danger.

Ne pas souder dans des endroits situés à proximité d’opérations de dé-

graissage, 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 galvani-

sé, 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 si néces-

saire, en portant un respirateur à alimentation d’air. Les revêtements et

tous les métaux renfermant ces éléments peuvent dégager des fumées

toxiques en cas de soudage.

OM-491 Page 6 Revenez à la table des matières

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.

Le rayonnement de l’arc du procédé de soudage génère

des rayons visibles et invisibles intenses (ultraviolets et

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la

peau. Des étincelles sont projetées pendant le soudage.

LES RAYONS DE L’ARC peuvent pro-

voquer des brûlures dans les yeux et

sur la peau.

Porter un casque de soudage muni d’un écran de filtre approprié pour pro-

téger votre visage et vos yeux pendant le soudage ou pour regarder (voir

ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

Porter des protections approuvés pour les oreilles si le niveau sondre est

trop élevé.

Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de

l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

Porter des vêtements de protection constitué dans une matière durable, ré-

sistant au feu (laine ou cuir) et une protection des pieds.

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.

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

chaud.

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

substances inflammables.

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.

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 che-

mins inconnus éventuels en provoquant des risques d’électrocution 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-électro-

de 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

chaussures 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 proxi-

mité.

DES PARTICULES VOLANTES

peuvent blesser les yeux.

Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent

des étincelles et des particules métalliques vo-

lantes. Pendant la période de refroidissement des soudures, elles ris-

quent de projeter du laitier.

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

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

Prévoir une période de refroidissement avant d’effec-

tuer des travaux d’entretien.

Porter des gants et des vêtements de protection pour

travailler sur un moteur chaud.

Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces

récemment soudées.

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 niveau sondre 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 opérations 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 normale-

ment partie du procédé de soudage, les manipuler avec

précaution.

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

chocs mécaniques, 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

électriques.

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

Une électrode de soudage ne doit jamais entrer en contact avec une bou-

teille.

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

Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et

raccords 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.

Lire et suivre les instructions concernant les bouteilles de gaz comprimé,

les équipements associés et les publication P-1 CGA énumérées dans les

normes de sécurité.

2-3. Dangers existant en relation avec le moteur

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.

OM-491 Page 7

Revenez à la table des matières

L’EXPLOSION DE LA BATTERIE peut

RENDRE AVEUGLE.

Toujours porter une protection faciale, des gants en

caoutchouc et vêtements de protection lors d’une in-

tervention 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 véhi-

cules 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 pro-

voquer un incendie ou une explosion.

Arrêter le moteur avant de vérifier le niveau de carbu-

rant ou de faire le plein.

Ne pas faire le plein en fumant ou proche d’une sour-

ce 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 carbu-

rant renversé avant de faire démarrer le moteur.

Jeter les chiffons dans un récipient ignifuge.

DES ORGANES MOBILES peuvent

provoquer des blessures.

Ne pas approcher les mains des ventilateurs, cour-

roies et autres pièces en mouvement.

Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de

protection.

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

Demander seulement à un personnel qualifié d’enlever les dispositifs de

sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’en-

tretien 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 orga-

nes mobiles.

Remettre en place les panneaux ou les dipositifs 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.

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’ex-

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

dans la section maintenance du manuel du moteur).

Si le moteur est chaud et que le liquide doit être vérifié, opérer comme sui-

vant :

Mettre des lunettes de sécurité et des gants, placer un torchon sur le bou-

chon du radiateur.

Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant

d’enlever le bouchon.

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 cause

la mort.

Ne pas utiliser l’air comprimé pour respirer.

Utiliser l’air comprimé seulement pour le coupa-

ge, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoque

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 sys-

tème avant d’effectuer la maintenance, avant de

changer 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

inflammables.

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 élé-

ments du circuit air comprimé chauds.

Laisser l’ensemble se refroidir avant de toucher

ou d’effectuer la maintenance.

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’effectuer la maintenance.

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

maintenance

LA CHUTE DE L’APPAREIL peut

blesser.

Utiliser l’anneau de levage uniquement pour soulever

l’appareil lui-même ; sans chariot, de bouteilles de

gaz, remorque, ou autres accessoires.

Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

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.

OM-491 Page 8 Revenez à la table des matières

LE SURCHAUFFEMENT peut endom-

mager le moteur électrique.

Arrêter ou déconnecter l’équipement avant de dé-

marrer 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 ris-

quent de provoquer des blessures.

Porter un écran facial pour protéger le visage et les

yeux.

Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de pro-

tecteurs. Cette manoeuvre 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

inflammable.

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

comme indiqué dans le manuel s’y rapportant.

LIRE LES INSTRUCTIONS.

Utiliser seulement les pièces de rechange d’origine.

Effectuer la maintenance du moteur et du compres-

seur (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 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 interférences pour l’équipement électronique

sensible tel que les ordinateurs et l’équipement com-

mandé par ordinateur 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. Principales normes de sécurité

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

l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (télé-

phone : (305) 443−9353, site Web : www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cutting

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

l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (télé-

phone : (305) 443−9353, site Web : www.aws.org).

National Electrical Code, norme NFPA 70, de la National Fire Protection As-

sociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101

(téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de

la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite

1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web :

www.cganet.com).

Code for Safety in Welding and Cutting, norme CSA W117.2, de la Cana-

dian Standards Association, Standards Sales, 178 boulevard Rexdale,

Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à To-

ronto : (416) 747−4044, site Web : www.csa−international.org).

Practice For Occupational And Educational Eye And Face Protection,

norme ANSI Z87.1, de l’American National Standards Institute, 11 West

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

Web : www.ansi.org).

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

norme NFPA 51B, de la National Fire Protection Association, P.O. Box

9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)

770−3000, site Web : www.nfpa.org et www.sparky.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 l’U.S. Government Printing Office, Superintendent

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

régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site

Web : www.osha.gov).

2-7. Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnétiques

basse fréquence sur l’organisme

En parcourant les câbles de soudage, le courant crée des champs électro-

magnétiques. Les effets potentiels de tels champs restent préoccupants.

Cependant, après avoir examiné plus de 500 études qui ont été faites pen-

dant une période de recherche de 17 ans, un comité de spécialistes du

National Research Council a conclu : « L’accumulation de preuves n’a pas

démontré que l’exposition aux champs magnétiques et aux champs électri-

ques à haute fréquence constitue un risque pour la santé humaine ».

Toutefois, les études et l’examen des preuves se poursuivent. En attendant

les conclusions finales de la recherche, il serait souhaitable de réduire l’ex-

position aux champs électromagnétiques pendant le soudage ou le

coupage.

Afin de réduire les champs électromagnétiques en milieu de travail, respec-

ter les consignes suivantes :

1. Garder les câbles ensemble en les torsadant ou en les fixant avec du

ruban adhésif.

2. Mettre tous les câbles du côté opposé à l’opérateur.

3. Ne pas s’enrouler les câbles autour du corps.

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

5. Placer la pince de masse le plus près possible de la zone de soudage.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout

consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-

mandé de respecter les consignes ci-dessus.

OM-491 Page 9Return To Table Of Contents

SECTION 3 − DEFINITIONS

3-1. Symbols And Definitions

Stop Engine Fast (Run, Weld/

Power) Slow (Idle) Start Engine

Starting Aid Battery (Engine) Engine Oil

Pressure Engine Oil

Check Injectors/

Pump Check Valve

Clearance Fuel Protective Earth

(Ground)

Positive Negative Certified/Trained

Mechanic Welding Arc

Amperes 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

Three Phase Read Operator’s

Manual Circuit Breaker Do Not Switch

While Welding

Electrode

Connection Work Connection Contactor On

SECTION 4 − SPECIFICATIONS

A CC/DC model is shown in this manual.

NOTE

OM-491 Page 10 Return To Table Of Contents

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

55 − 600 A

(CC Models)

20 − 600 A

(CC/CV Models)

400 A, 40 Volts DC,

100% Duty Cycle

500 A, 40 volts DC,

60% Duty Cycle

Standard

Single-Phase,

4 kVA/kW, 34/17 A,

120/240 V AC,

50/60 Hz

Three-Phase Generator

Option*

Perkins 3.1524

Perkins

25 gal

(95 L)

CV/DC

(CC/CV

Models

Only)

14 − 40 V

500 A, 40 volts DC,

60% Duty Cycle

600 A, 30 Volts DC,

40% Duty Cycle 56

Three-Phase Generator

Option*

Single-Phase/Three-Phase

12/20 kVA/kW, 50/48A,

120/240 VAC, 60 Hz

*In Addition To Standard

4 kVA/kW Generator Power

Perkins 3.1524

Water-Cooled,

Three-Cylinder,

45 HP Diesel Engine

25 gal

(95 L)

4-2. Dimensions, Weights, And Operating Angles

Dimensions

Height 50 in (1270 mm)

(to top of muffler) G

Width

28-1/2 in (724 mm)

(mtg. brackets turned in)

30-3/4 in (781 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 65-1/8 in (1654 mm)

Do not move or operate unit where it could

tip.

A65-1/8 in (1654 mm)

B* 56 in (1422 mm)

C* 46-1/2 in (1181)

D* 9-5/8 in (244 mm)

E27-1/2 in (699 mm)

F1 in (25 mm)

G29-1/2 in (743 mm) H

H9/16 in (14 mm) Dia.

4 Holes

Front Panel End

30°

* With mounting brackets in center

position. Dimensions vary with

location of mounting brackets.

Front Panel End

20°

Weight

w/ Perkins

3.1524 No fuel: 1670 lb (758 kg)

w/fuel: 1860 lb (844 kg)

802 161-A

OM-491 Page 11Return To Table Of Contents

4-3. Volt-Ampere Curves For CC Models

203 412

The volt-ampere curve shows the

minimum and maximum voltage

and amperage output capabilities of

the welding generator. Curves of all

other settings fall between the

curves shown.

100

0 100 200 300 400 500 600 700 800 900

DC AMPERES

DC VOLTS

Ranges

300−Max

185−425

125−320

85−190

55−90

OM-491 Page 12 Return To Table Of Contents

4-4. Volt-Ampere Curves For CC/CV Models

203 414 / 203 415 / 203 413

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

100

0 100 200 300 400 500 600 700 800 900

DC AMPERES

DC VOLTS

Ranges

300−Max

185−425

125−320

85−190

55−90

100

0 100 200 300 400 500 600 700 800 900 1000

DC AMPERES

DC VOLTS

MAX

MIN

100

0 50 100 150 200 250 300 350 400 450 500

DC AMPERES

DC VOLTS

Ranges

60−310

40−200

30−130

20−70

OM-491 Page 13Return To Table Of Contents

4-5. Fuel Consumption

The curve shows typical fuel use

under weld or power loads.

193 093

0 50 100 150 200 250 300 350 400 450 500

DC WELD AMPERES AT 100% DUTY CYCLE

1800 RPM

IDLE

Continuous Welding

4-6. 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 400 Amperes

089 697-D

OM-491 Page 14 Return To Table Of Contents

4-7. AC Generator Power Curve

193 018

The ac power curve shows the gen-

erator power in amperes available

at the 120 and 240 volt receptacles.

100

150

200

250

300

0 5 10 15 20 25 30

AC AMPERES IN 240V MODE

AC VOLTS

100

150

125

0102030405060

AC AMPERES IN 120V MODE

4-8. Optional Three-Phase Generator Curves

197 472 / 197 473

The ac power curves show the gen-

erator power available in amperes

at the single-phase 120/240 volt re-

ceptacle or three-phase 240 volt

terminals.

A. 12 kVA/kW Single-Phase AC Output (No Weld Load)

B. 20 kVA/kW Three-Phase AC Output (No Weld Load)

180

190

200

210

220

230

240

250

260

270

280

020 40 60 80 100

AC AMPERES

AC VOLTS

180

200

220

240

260

280

0 10203040506070

AC VOLTS

AC AMPERES

100

105

110

115

120

125

130

135

140

OM-491 Page 15Return To Table Of Contents

SECTION 5 − INSTALLATION

install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274

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.

See Section 5-2 for mounting in-

formation.

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

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm) 18 in

(460 mm)

18 in

(460 mm)

Movement

Airflow Clearance

5-1. Installing Welding Generator

OR 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.

Location

OM-491 Page 16 Return To Table Of Contents

5-2. Mounting Welding Generator

Tools Needed:

9/16 in

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.

Inadequate support.

Supporting The Unit

Using Mounting Brackets

install3 6/03 803 274 / 190 250-A / 803 231

Do not use flexible mounts.

OM-491 Page 17Return To Table Of Contents

5-3. Using Lifting Eye

Ref. 802 169-F

1 Lifting Eye

2 Nut

3 Carriage Bolt

Raise lifting eye until it snaps in

place. Lower lifting eye when not

needed.

To lock the lifting eye in the upright

position, insert a 3/8-16 x 1-1/2 in

carriage bolt through slot in bracket

and secure with nut (bolt and nut not

supplied).

Tools Needed:

5-4. Installing Exhaust Pipe

1/2 in

Tools Needed:

Ref. 802 169-E / Ref. 202 705

Stop engine and let cool.

Point exhaust pipe in desired di-

rection but always away from front

panel and direction of travel.

OM-491 Page 18 Return To Table Of Contents

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

Remove battery from unit.

1 Eye Protection − Safety

Glasses Or Face Shield

2 Rubber Gloves

3 Vent Caps

4 Sulfuric Acid Electrolyte

(1.265 Specific Gravity)

5 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.

6 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.

Tools Needed:

30 A For 12 Minutes

5 A For 30 Minutes

−

drybatt1 1/98 − 0886

rubber gloves

glasses

OM-491 Page 19Return To Table Of Contents

5-6. Connecting The Battery

1/2 in

−

Connect Negative (−) Cable Last.

Tools Needed:

802 168-E / Ref. 202 705 / 802 313 / S-0756-C

Reinstall cover after connecting batter

Notes

OM-491 Page 20 Return To Table Of Contents

Ref. 802 168-E

5-7. 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.

The Automatic shutdown system stops en-

gine if fuel level or oil pressure is too low, or

coolant temperature 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 11.

Fuel

Do not use gasoline. Gasoline will

damage engine.

The unit is shipped with enough fuel to pre-

vent air from entering fuel system but not

enough fuel to prevent low fuel shutdown.

Add fresh diesel fuel before starting to pre-

vent low fuel shutdown (see engine mainte-

nance 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 Starting Aid switch (see Section

6-1 or 7-1).

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 9-2).

Full

Capacity: 12 qt (11.4L)

Diesel

Full

Hot Full

Cold Full

Check radiator coolant level when

fluid is low in recovery tank.

Coolant Recovery Tank

OM-491 Page 21Return To Table Of Contents

5-8. Connecting To Weld Output Terminals

Ref. 802 169-E

Stop engine.

1 Positive (+) Weld Output Terminal

2 Negative (−) Weld Output Terminal

For Stick and TIG welding Direct Cur-

rent Electrode Positive (DCEP), con-

nect electrode holder cable to Positive

(+) terminal on left and work cable to

Negative (−) terminal on right.

For Direct Current Electrode Negative

(DCEN), reverse cable connections.

If equipped with optional polarity switch,

connect electrode holder cable to Elec-

trode terminal on left and work cable to

Work terminal on right.

For MIG and FCAW welding Direct Cur-

rent Electrode Positive (DCEP) on CC/

CV models, connect wire feeder cable to

Positive (+) terminal on left and work

cable to Negative (−) terminal on right.

Use Process/Contactor switch to select

type of weld output (see Section 7-3).

For Direct Current Electrode Negative

(DCEN), reverse cable connections.

If equipped with optional polarity switch,

connect wire feeder cable to Electrode

terminal on left and work cable to Work

terminal on right.

Tools Needed:

3/4 in

5-9. 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 (normally you can smell it), 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-E−

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

OM-491 Page 22 Return To Table Of Contents

5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models

Ref. 154 862-A / 048 720-K / 802 160-E

1 Remote Amperage Adjust

Receptacle RC13

Connect optional remote control to

RC13 (see Section 6-3).

5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models

Socket* Socket Information

24 VOLTS AC

A24 volts ac. Protected by circuit

breaker CB5.

24 VOLTS AC

BContact closure to A completes

24 volt ac contactor control

circuit.

New! LDR-14 long

COutput to remote control:+10

volts dc in MIG or Stick mode;

0 to +10 volts dc in TIG mode.

New! LDR-14 long

distance remote

(includes 120 V

receptacle)

REMOTE

OUTPUT

CONTROL

DRemote control circuit common.

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.

115 VOLTS AC

I115 volts, 10 amperes, 60 Hz

ac. Protected by circuit breaker

CB6.

JContact closure to I completes

115 volt ac contactor control

circuit.

802 169-F GND K Chassis common.

NEUTRAL GCircuit common for 24 and 115

volt ac circuit.

*The remaining sockets are not used.

OM-491 Page 23Return To Table Of Contents

SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS

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

202 705 / 802 169-F

15 16

13 18 1914 1210 11

OM-491 Page 24 Return To Table Of Contents

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

Engine Starting Controls

1 Magnetic Shutdown Switch

Use switch during start-up to bypass engine

shutdown system. System stops engine if oil

pressure or fuel level is too low or coolant tem-

perature is too high.

2 Starting Aid Switch

Use switch to energize starting aid for cold

weather starting (see starting instructions fol-

lowing).

3 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 Run/Idle position (optional), engine

runs at idle speed at no load and weld speed

with load applied.

To Start:

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 while pressing Shutdown

switch. Release Engine Control switch when

engine starts. Continue holding Shutdown

switch until engine indicator lights go out.

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

to Run/Idle position. Push Starting Aid switch

up for 60 seconds. While still holding Starting

Aid switch, press Magnetic Shutdown switch

and turn Engine Control switch to Start. Re-

lease Engine Control switch and Starting Aid

switch when engine starts. Continue holding

Shutdown switch until engine indicator lights

go out.

To Stop: turn Engine Control switch to Off

position.

Engine Indicator Lights

4 Battery Charging Light

Light goes on if engine alternator is not charg-

ing battery. Engine continues to run.

Stop engine and fix trouble if Battery

Charging light goes on.

5 Engine Temperature Light

Light goes on and engine stops if engine tem-

perature is above 221 ° F (105° C).

Stop engine and fix trouble if Engine

Temperature light goes on.

6 Engine Oil Pressure Light

Light goes on and engine stops if oil pressure

is below 10 psi (69 kPa). Light goes on mo-

mentarily during start-up but goes out when

engine reaches normal oil pressure.

Stop engine and fix trouble if Engine

Oil Pressure light stays on after start-

up.

7 Fuel Light

Light goes on and engine stops if fuel level is

low. Add fuel to resume operation.

8 Engine Hour Meter

Engine Gauges

To read gauges and engine indicator

lights with engine off, turn Engine Control

switch to Run/Idle and press Magnetic

Shutdown switch (see Section 9-8).

9 Fuel Gauge

Use gauge to check fuel level.

To check fuel level when engine is not run-

ning, turn Engine Control switch to Run/Idle

position and press Magnetic Shutdown

switch.

10 Battery Voltmeter (Optional)

Use gauge to check battery voltage and moni-

tor the engine charging system. The meter

should read about 14 volts dc when the en-

gine is running, and about 12 volts dc when

the engine is stopped.

11 Engine Coolant Temperature Gauge

(Optional)

Normal temperature is 180 - 203° F (82 - 95°

C). When equipped with gauge option, engine

stops if temperature exceeds 220° F (104° C).

12 Engine Oil Pressure Gauge (Optional)

Normal pressure is 30 − 60 psi (207 − 414

kPa). When equipped with gauge option, en-

gine stops if pressure is below 10 psi (69

kPa).

Weld Controls

Max OCV Control Circuit: This unit has

a max OCV control circuit that resets Am-

perage Adjust control R1 to maximum

when the arc breaks. When an arc is

struck, weld output control returns to the

R1 front panel or combination front panel/

remote control setting. The Amperage

Adjust control adjusts amperage only

when welding and does not adjust open-

circuit voltage.

The max OCV circuit is disabled when

the Stick/TIG Selection switch is in

Scratch Start TIG position (see item 15).

13 Ampere Range Switch

Do not switch under load.

Use switch to select weld amperage range.

For most welding applications, use lowest

amperage range possible to help prevent arc

outages.

14 Amperage Adjust Control

Control adjusts amperage within range se-

lected by Ampere Range switch. Weld output

would be about 223 A DC with controls set as

shown (50% of 125 to 320 A).

The numbers around the control are for

reference only and do not represent an

actual percentage value.

15 Stick/TIG Selection Switch

Use switch to disable the max OCV circuit

and the arc drive (dig) circuit for scratch start

TIG welding (see max OCV note under Weld

Controls).

When switch is in the Stick position, the max

OCV circuit resets Amperage Adjust Control

R1 to maximum when the arc breaks.

Also in the Stick position, the arc drive (dig)

circuit provides additional amperage during

low voltage (short arc length conditions) to

prevent “sticking” electrodes.

When switch is in Scratch Start TIG position,

the max OCV and arc drive (dig) circuits are

disabled and OCV changes when the control

is adjusted.

16 Amperage Adjust Switch And Remote

Amperage Adjust Receptacle

Connect optional remote control to RC13

(See Section 5-10). Use switch to select front

panel or remote amperage control. For re-

mote control, place switch in Remote position

and connect remote control to Remote Am-

perage Adjust receptacle RC13 (see Sec-

tions 5-10 and 6-3).

17 Polarity Switch (Optional)

Do not switch under load.

Use switch to change weld output. Select ei-

ther DC Electrode Positive (DCEP) or DC

Electrode Negative (DCEN).

Weld Meters

18 DC Voltmeter (Optional)

Voltmeter displays voltage at the weld output

terminals, but not necessarily the welding arc

due to resistance of cable and connections.

19 DC Ammeter (Optional)

Ammeter displays amperage output of the

unit.

OM-491 Page 25Return To Table Of Contents

6-3. Remote Amperage Control On CC Models (Optional)

1 Remote Amperage Adjust

Receptacle RC13

Connect optional remote control to

RC13 (see Section 5-10).

Example: Combination Remote Amperage Control (Stick) In Example:

Range = 125 to 320 A DC

Percentage Of Range = 50%

Max = About 223 A DC (50% of 125 to 320)

Adjust Optional Remote ControlSet Switches Set Range Set Control

Max (223 A DC)

Min (87 A DC)

0774 / Ref. 154 862-A / Ref. 181 711-A / 802 160-D

6-4. Weld Control/Arc Condition Information Label

Set weld controls as shown to

achieve softer or stiffer arc condi-

tions for different applications.

212 944-A

OM-491 Page 26 Return To Table Of Contents

Notes

OM-491 Page 27Return To Table Of Contents

SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS

7-1. Front Panel Controls For CC/CV Models (See Section 7-2)

202 706 / 802 311-D

13 16

14 18 1915 1210 11

OM-491 Page 28 Return To Table Of Contents

7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)

Engine Starting Controls

1 Magnetic Shutdown Switch

Use switch during start-up to bypass engine

shutdown system. System stops engine if oil

pressure is too low or engine temperature is

too high.

2 Starting Aid Switch

Use switch to energize starting aid for cold

weather starting (see starting instructions fol-

lowing).

3 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 Run/Idle position (optional), engine

runs at idle speed at no load and weld speed

with load applied.

To Start:

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 while pressing Shutdown

switch. Release Engine Control switch when

engine starts. Continue holding Shutdown

switch until engine indicator lights go out.

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

to Run/Idle position. Push Starting Aid switch

up for 60 seconds. While still holding Starting

Aid switch, press Magnetic Shutdown switch

and turn Engine Control switch to Start. Re-

lease Engine Control switch and Starting Aid

switch when engine starts. Continue holding

Shutdown switch until engine indicator lights

go out.

To Stop: turn Engine Control switch to Off

position.

Engine Indicator Lights

4 Battery Charging Light

Light goes on if engine alternator is not charg-

ing battery. Engine continues to run.

Stop engine and fix trouble if Battery

Charging light goes on.

5 Engine Temperature Light

Light goes on and engine stops if engine tem-

perature is above 221 ° F (105° C).

Stop engine and fix trouble if Engine

Temperature light goes on.

6 Engine Oil Pressure Light

Light goes on and engine stops if oil pressure

is below 10 psi (69 kPa). Light goes on mo-

mentarily during start-up but goes out when

engine reaches normal oil pressure.

Stop engine and fix trouble if Engine

Oil Pressure light stays on after start-

up.

7 Fuel Light

Light goes on and engine stops if fuel level is

low. Add fuel to resume operation.

8 Engine Hour Meter

Engine Gauges

To read gauges and engine indicator

lights with engine off, turn Engine Control

switch to Run/Idle and press Magnetic

Shutdown switch (see Section 9-8).

9 Fuel Gauge

Use gauge to check fuel level.

To check fuel level when engine is not run-

ning, turn Engine Control switch to Run/Idle

position and press Magnetic Shutdown

switch.

10 Battery Voltmeter (Optional)

Use gauge to check battery voltage and moni-

tor the engine charging system. The meter

should read about 14 volts dc when the en-

gine is running, and about 12 volts dc when

the engine is stopped.

11 Engine Coolant Temperature Gauge

(Optional)

Normal temperature is 180 - 203° F (82 - 95°

C). When equipped with gauge option, engine

stops if temperature exceeds 220° F (104° C).

12 Engine Oil Pressure Gauge (Optional)

Normal pressure is 30 − 60 psi (207 − 414

kPa). When equipped with gauge option, en-

gine stops if pressure is below 10 psi (69

kPa).

Weld Controls

13 Process/Contactor Switch

See Section 7-3 for Process/Contactor

switch information.

14 Ampere Range Switch

Use switch to select weld amperage range.

Use the lowest four ranges for Stick and TIG

welding. Read the upper set of numbers at

each range for Stick welding and the lower set

at each range for TIG welding.

Use the highest range for MIG welding and for

cutting and gouging (CAC-A).

For most welding applications, use lowest

amperage range possible to help prevent arc

outages.

Do not switch under load.

15 Voltage/Amperage Adjust Control

With Process/Contactor switch in any Stick or

TIG setting, use control to adjust amperage

within range selected by Ampere Range

switch. With Process/Contactor switch in any

MIG position, use control to adjust voltage.

With Voltage/Amperage Adjust Switch in Re-

mote position, control limits the remote am-

perage in TIG mode, but has no effect in Stick

and MIG modes.

Weld output would be about 223 A DC with

controls set as shown (50% of 125 to 320 A).

The numbers around the control are for

reference only and do not represent an

actual percentage value.

16 Voltage/Amperage Adjust Switch And

Remote 14 Receptacle

Use switch to select front panel or remote

voltage/amperage control. For remote con-

trol, place switch in Remote position and con-

nect remote control to Remote 14 receptacle

RC14 (see Sections 5-11 and 7-4).

17 Polarity Switch (Optional)

Do not switch under load.

Use switch to change weld output. Select ei-

ther DC Electrode Positive (DCEP) or DC

Electrode Negative (DCEN).

Weld Meters

18 DC Voltmeter (Optional)

Voltmeter displays voltage at the weld output

terminals, but not necessarily the welding arc

due to resistance of cable and connections.

19 DC Ammeter (Optional)

Ammeter displays amperage output of the

unit.

OM-491 Page 29Return To Table Of Contents

7-3. Process/Contactor Switch On CC/CV Models

1 Process/Contactor Switch

Weld output terminals are ener-

gized when Process/Contactor

switch is in an Electrode Hot

position and the engine is run-

ning.

DC voltage is still present at the

weld terminals when Process/

Contactor switch is in the

Remote − Stick position and the

engine is running.

Use switch to select weld process and

weld output on/off control (see table be-

low and Section 7-4).

Place switch in Remote positions to

turn weld output on and off with a de-

vice connected to the remote 14 recep-

tacle.

Place switch in Electrode Hot positions

for weld output to be on whenever the

engine is running.

Use Stick position for air carbon arc

(CAC-A) cutting and gouging.

When switch is in a Stick position, the

arc drive (dig) circuit provides addition-

al amperage during low voltage (short

arc length conditions) to prevent “stick-

ing” electrodes.

The arc drive (dig) circuit is disabled

when switch is in MIG or TIG positions.

Place switch in Electrode Hot -

Stick position when using optional

three-phase generator (see Sec-

tion 8-2).

The engine auto idle option does

not work in the Remote-TIG mode.

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 − TIG GTAW With HF Unit, Pulsing

Device, Or Remote Control At Remote 14 Receptacle Not Active

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

Remote − MIG MIG (GMAW) At Remote 14 Receptacle Active

Electrode Hot − MIG MIG (GMAW) Electrode Hot Active

Electrode Hot − Stick Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting

And Gouging Electrode Hot Active

Electrode Hot − Scratch

Start TIG Scratch Start TIG (GTAW) Electrode Hot Active

OM-491 Page 30 Return To Table Of Contents

7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)

1 Remote 14 Receptacle RC14

Connect optional remote control to

RC14 (see Section 5-11).

0774 / Ref. 202 706 / 802 169-E

Example: Combination Remote Amperage Control (Stick) In Example:

Process = Stick (Using Remote On/Off)

Range = 125 to 320 A DC

Min = 125 A DC

Max = 320 A DC

Adjust Optional Remote Control

Set V/A

Adjust Switch Set Range Control Not

Used In Remote

Stick Mode

Max (320 A DC)

Min (125 A DC)

Set Remote

Process

Example: Combination Remote Amperage Control (TIG) In Example:

Process = TIG (Using Remote On/Off)

Range = 40 to 200 A DC

Percentage Of Range = 50%

Min = 40 A DC

Max = About 120 A DC (50% of 40 to 200)

Adjust Optional Remote Control

Set V/A

Adjust Switch Set Range Set Control

Max (120 A DC)

Min (40 A DC)

Set Remote

Process

OM-491 Page 31Return To Table Of Contents

SECTION 8 − OPERATING AUXILIARY EQUIPMENT

8-1. 120 Volt And 240 Volt Receptacles

191 624-A

1 120 V 20 A AC GFCI

Receptacle GFCI1

2 240 V 30 A AC Twistlock

Receptacle RC1

Receptacles supply 60 Hz single-

phase power at weld/power speed.

If a ground fault is detected, GFCI

Reset button pops out and

receptacle does not work. Check

for faulty tools plugged in

receptacle. Press button to reset

GFCI1.

At least once a month, run en-

gine at weld/power speed and

press test button to verify GFC

is working properly.

3 Circuit Breaker CB1

4 Circuit Breaker CB2

CB1 protects RC1 and the genera-

tor winding from overload. If CB1

opens, RC1 and GFCI1 do not

work. Place switch in On position to

reset breaker.

CB2 protects GFCI1 from overload.

If CB2 opens, GFCI1 does not

work. Press button to reset breaker.

If a circuit breaker continues to

open, contact Factory Autho-

rized Service Agent.

Generator power is not af-

fected by weld output.

Maximum output is 2.4 kVA/kW

from GFCI1 and 4 kVA/kW from

RC1. Maximum output from all re-

ceptacles is 4 kVA/kW.

EXAMPLE: If 13 A is drawn from

RC1, only 7 A is available at GFCI1:

(240 V x 13 A) + (120 V x 7 A) =

4.0 kVA/kW

OM-491 Page 32 Return To Table Of Contents

8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)

Ref. 197 399 / 802 332-E

Place Process/Contactor switch

in Electrode Hot - Stick position

when using three−phase genera-

tor (see Section 7-3).

Single-Phase Generator Power

1 120/240 V 50 A Receptacle

RC5

RC5 is connected to the optional

three−phase generator and supplies

60 Hz single-phase power at weld/

power speed. Maximum output from

RC5 is 12 kVA/kW. Power available

at RC5 is reduced when welding.

2 Circuit Breaker CB7

Circuit breaker CB7 protects single-

phase receptacle RC5 and the load

wires from overload. If CB7 opens, all

generator output stops and the recep-

tacle does not work.

Three-Phase Generator Power

Stop engine.

Power and weld outputs are

live at the same time. Discon-

nect or insulate unused

cables.

Have qualified person install ac-

cording to circuit diagram and

Generator Power Guidelines

(see Section 12).

Remove generator power panel

mounting screws. Tilt panel forward.

3 Lead 93

4 Lead 92

5 Lead 91

6 Lead 42 (Circuit Grounding

Lead)

7 Lead 90 (Neutral)

8 Isolated Neutral Terminal

9 Jumper Lead 42

10 Grounding Terminal

Jumper 42 is connected to lead 90 at

factory. Jumper 42 may be discon-

nected from neutral to meet applica-

ble electrical codes.

Lead 42 connects to front panel

Ground stud.

11 User-Supplied Leads

12 Circuit Breaker CB7 User

Terminals

Connect user-supplied leads to ter-

minals on CB7 and to the isolated

neutral terminal and grounding termi-

nal as necessary.

Circuit breaker CB7 protects

single-phase receptacle RC5

and the load wires from overload.

If CB7 opens, all generator out-

put stops and the receptacle

does not work.

Reinstall generator power panel.

Tools Needed:

Volts

Amps

KVA/KW

Single

120/240

Three

240

60 HzFrequency

Engine Speed 1850 RPM

AC Phase

1 Phase

Output

Lead 42 connects to GROUND stud on

front of unit.

Jumper 42 is connected to 90 at factory.

91 92 93

240V

120V

240V

1-Phase

Three-Phase

Rear Of Panel

Three-Phase Power Connection

Single-Phase Power Connection

Close panel opening

if no connections are

made to generator.

Close panel

opening if no

connections

are made to

power plant.

240V

Remove plug

before inserting

leads. Reinstall

bushing.

OM-491 Page 33Return To Table Of Contents

8-3. Optional Generator Power Receptacles

1 120 V 20 A AC GFCI

Receptacle GFCI1

2 240 V 16 A AC European

Receptacle RC1

3 240 V 15 A AC Australian

Receptacle RC1

4 240 V 15 A AC South African

Receptacle RC1

Receptacles supply 60 Hz single-

phase power at weld/power speed.

If a ground fault is detected, the

GFCI Reset button pops out and

the receptacle does not work.

Check for faulty tools plugged in

receptacle. Press button to reset

GFCI1.

At least once a month, run en-

gine at weld/power speed and

press test button to verify GFCI

is working properly.

5 Circuit Breaker CB2

6 Circuit Breaker CB3

CB2 protects GFCI1 from overload.

If CB2 opens, GFCI1 does not

work. Press button to reset breaker.

CB3 protects RC1 from overload. If

CB3 opens, RC1 does not work.

Press button to reset breaker.

If a circuit breaker continues to

open, contact Factory Autho-

rized Service Agent.

Generator power is not af-

fected by weld output.

Maximum output is 2.4 kVA/kW

from GFCI1 and 4 kVA/kW from

RC1. Maximum output from all re-

ceptacles is 4 kVA/kW.

EXAMPLE: If 13 A is drawn from

RC1, only 7 A is available at GFCI1:

(240 V x 13 A) + (120 V x 7 A) =

4.0 kVA/kW

191 624

European Receptacle

Australian Receptacle

South African Receptacle

OM-491 Page 34 Return To Table Of Contents

SECTION 9 − MAINTENANCE & TROUBLESHOOTING

9-1. Routine Maintenance

Follow the storage procedure in the engine owner’s manual if the unit will not be used for an

extended period.

Note

Recycle engine

fluids.

Stop engine before maintaining.

See Engine Manual and Maintenance

Label for important start-up, service,

and storage information. Service unit

more often if used in severe conditions.

* To be done by Factory Authorized

Service Agent.

Every 8 h

Check Fluid

Levels. See

Section 5-7.

Wipe

Spills.

Drain Water

From Fuel

System.

OIL

Full

FUEL

WATER

Coolant

Full

Every 50 h

Clean Air Filter.

See Section 9-3.

Clean And

Tighten

Weld

Terminals.

Every 100 h

Clean And

Tighten

Battery

Connections.

Check air cleaner

hoses for cracks

and loose clamps.

Every 200 h

1/2 in.

(13 mm) Check Belt

Tension.

Every 250 h

Check And

Clean Spark

Arrestor. See

Section 9-4.

Replace

Unreadable

Labels.

Continued on next page.

OM-491 Page 35Return To Table Of Contents

Every 400 h

Change Oil. See

Section 9-6.

Change Oil

Filter. See

Section 9-6.

Check Radiator

Fluid Level. See

Section 5-7.

Change Fuel

Filters. See

Section 9-6.

Check

Valve

Clearance.*

Every 500 h

Repair Or

Replace

Damaged

Cables.

Every 800 h

Clean/Set

Injectors.*

Every 1000 h

Blow Out Or

Vacuum Inside.

During Heavy

Service,

Clean Monthly.

OR Drain Sludge

From Fuel

Tank. See

Section 9-6.

FUEL

SLUDGE

Service Welding Generator

Brushes And Slip Rings. Service

More Often In Dirty Conditions.*

OM-491 Page 36 Return To Table Of Contents

9-2. Maintenance Label

OM-491 Page 37Return To Table Of Contents

9-3. Servicing Air Cleaner

aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 202 705

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

Keep nozzle

2 in (51 mm)

from element.

Optional

OM-491 Page 38 Return To Table Of Contents

9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler

802 160-E / Ref. 202 705

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

OM-491 Page 39Return To Table Of Contents

9-5. Adjusting Engine Speed

802 168-C / 802 229-A / Ref. 202 705

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.

On CC Models, place Stick/TIG

switch in Stick position.

On CC/CV models, turn Process/

Contactor switch to Stick − Elec-

trode Hot position.

Standard Models

1 Adjustment Screw

2 Lock Nut

Loosen nuts. Turn screws out sev-

eral turns.

3 Speed Lever

Start engine and move lever until

engine runs at weld/power speed.

Tighten adjustment screws and

lock nuts.

Do not set engine speed higher

than specified.

Models With Automatic Idle

(Optional)

Idle Speed Adjustment

4 Throttle Rod/Plunger

5 Locknut

Loosen locknut. Place Engine Con-

trol switch in Run/Idle position.

Turn throttle rod and plunger until

engine runs at idle speed. Tighten

locknut.

Be sure solenoid plunger pulls

all the way in (“bottoms”) when

energized.

Weld/Power Speed Adjustment

6 Engine Weld/Power Speed

Adjustment Screw

7 Locknut

Place Engine Control switch in Run

position.

Loosen locknut. Turn screw until

engine runs at weld/power speed.

Tighten locknut.

Do not set engine speed higher

than specified.

Stop engine.

Close door.

Tools Needed:

5/16 in

1850 rpm

(61.6 Hz)

1500 rpm

(50 Hz)

Weld/Power

Idle

Engine Speed

(No Load)

Standard Models

Models With Automatic Idle (Optional)

OM-491 Page 40 Return To Table Of Contents

9-6. Servicing Fuel And Lubrication Systems

802 170-D / Ref. 802 168-B / 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 Fuel Line

5 Primary Fuel Filter (Fuel/

Water Separator)

6 Petcock

7 Secondary Fuel Filter

8 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 drain water from fuel system:

Open primary fuel filter petcock and

drain water into metal container.

Close petcock when water-free fuel

flows.

To replace primary 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. Bleed air from fuel system ac-

cording to engine manual.

Inspect fuel lines, and replace if

cracked or worn.

To replace secondary fuel filter:

See engine manual.

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:

OM-491 Page 41Return To Table Of Contents

9-7. Overload Protection

802 170-E

Stop engine.

When a circuit breaker or fuse

opens, it usually indicates a

more serious problem exists.

Contact Factory Authorized

Service Agent.

1 Fuse F1

2 Fuse F2

F1 and F2 protect the stator exciter

winding from overload. If F1 opens,

weld and generator power is low or

stops entirely. If F2 opens, weld out-

put is low or stops entirely. 4 kVA/

kW generator power is still avail-

able.

3 Circuit Breaker CB4 (Not

Shown)

4 Circuit Breaker CB5

(CC/CV Models Only)

5 Circuit Breaker CB6

(CC/CV Models Only)

6 Circuit Breaker CB10 (Not

Shown)

7 Circuit Breaker CB11

8 Circuit Breaker CB12

9 Circuit Breaker CB13

CB4 protects the welding arc drive

(dig) circuit. If CB4 opens, electro-

de may stick to the workpiece more

frequently during low voltage (short

arc length) conditions. CB4 auto-

matically resets when the fault is

corrected.

CB5 protects the 24 volt ac output

to remote receptacle RC14, and 24

volt output to field current regulator

board PC1 (CC/CV models only). If

CB5 opens, weld output and 24 volt

output to RC14 stops. On units with

optional three−phase generator,

output at receptacle RC5 also stops

if CB5 opens.

CB6 protects the 115 volt ac output

to remote receptacle RC14 (CC/CV

models only). If CB6 opens, 115 volt

output to RC14 stops.

CB10 protects the engine battery

circuit. If CB10 opens, the engine

will not crank. CB10 automatically

resets when the fault is corrected.

CB11 protects the engine wiring

harness. On CC models, if CB11

opens the max OCV circuit does

not work and open circuit voltage is

variable at all times (see max OCV

note under Weld Controls in Sec-

tion 6-2). If CB11 opens on CV mod-

els, weld output stops (generator

power is still available).

CB12 protects the field flashing cir-

cuit. If CB12 opens, the generator

may not excite at start-up and weld

and generator power output may

not be available.

CB13 protects the engine shut-

down circuit. If CB13 opens, the en-

gine cranks but does not start.

Press button to reset breaker.

OM-491 Page 42 Return To Table Of Contents

9-8. Diagnosing Causes Of Engine Fault Shutdowns

Ref. 202 705

Use the front panel engine lights to

help determine the cause of an au-

tomatic engine shutdown.

Correct the cause of the shut-

down before operating the

welding generator.

This unit does not have a bat-

tery charging fault shutdown.

The engine continues to run if

the Battery Charging Light

goes on.

Normal Condition:

Oil Pressure Light On;

Battery Charging, Fuel, And Temperature Lights Off.

If Oil Pressure Light Is Off, See Factory Authorized Service Agent.

If Battery Charging Light Is On, Have Factory Authorized Service Agent

Check Alternator.

If Temperature Light Is On, Correct Cause Of Overheating

(See Engine Manual).

If Fuel Light Is On, Check Fuel Level.

If Engine Is Okay, See Factory Authorized Service Agent.

Start Engine (With No Load Applied). Continue Pressing Shutdown Switch

Until Engine Lights Go Off. Normal Condition:

Engine Lights Go Off As Engine Reaches

Normal Operating Condition.

Lights That Stay On After 20 Sec. Indicate Fault

Condition.

Stop Engine And Correct Fault (See Above) If Fault

Continues, See Factory Authorized Service Agent.

Turn Engine Control Switch To Run/Idle

Position While Pressing Magnetic

Shutdown Switch.

20s

Pre-Start Diagnostic Checks

Diagnostic Checks While Running

OM-491 Page 43Return To Table Of Contents

9-9. Troubleshooting

A. Welding − CC Models

Trouble Remedy

No weld output; generator power output

okay at ac receptacles. Check position of Ampere Range switch.

Check position of optional polarity switch.

Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote

control to Remote Amperage Adjust receptacle RC13 (see Sections 5-10 and 6-1).

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-10).

Check fuse F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent check inte-

grated rectifier SR2 and the rotor.

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

No weld output or generator power out-

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

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (see Section 9-7).

Have Factory Authorized Service Agent check brushes and slip rings, 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. Check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent check OCV control circuit.

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

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

Electrode sticks to the workpiece more

frequently during low voltage (short arc

length) conditions.

Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-7).

Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.

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

Maximum weld output only in each

ampere range (with Stick/TIG Selection

switch in Stick position).

Have Factory Authorized Service Agent check control relay CR7.

No remote fine amperage control. Place Amperage Adjust switch in correct position.

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-10).

Reset circuit breaker CB11 (see Section 9-7). Have Factory Authorized Service Agent check control relay

CR7.

Repair or replace remote control device.

Have Factory Authorized Service Agent check OCV control circuit.

OM-491 Page 44 Return To Table Of Contents

B. Welding − CC/CV Models

Trouble Remedy

No weld output; generator power output

okay at ac receptacles. Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and

connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-11 and 7-1).

Check position of Ampere Range switch.

Check position of optional polarity switch.

Reset circuit breaker CB11 (see Section 9-7).

Reset circuit breaker CB5 or CB6 (see Section 9-7). Check for faulty remote device connected to

RC14.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).

Have Factory Authorized Service Agent check connector board PC6 and connections.

Check fuse F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent check

brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor.

No weld output or generator power out-

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

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

Have Factory Authorized Service Agent check brushes and slip rings, 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. Check position of Ampere Range switch and Voltage/Amperage Adjust control.

Check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent check field current regulator board PC1.

Voltage/Amperage control does not

work when welding in Stick mode. Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere

Range switch in highest range.

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

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

Electrode sticks to the workpiece more

frequently during low voltage (short arc

length) conditions.

Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-7).

Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.

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

No remote fine amperage or voltage

control. Place Voltage/Amperage Adjust switch in Remote position.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).

Repair or replace remote control device.

Constant speed wire feeder does not

work. Reset circuit breaker CB5 or CB6 (see Section 9-7).

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).

Repair or replace wire feeder.

Low CV weld output. Set Ampere Range switch to highest range.

OM-491 Page 45Return To Table Of Contents

Trouble Remedy

Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.

Repair or replace remote control device.

Have Factory Authorized Service Agent check field current regulator board PC1.

C. Standard Generator Power

Trouble Remedy

No generator power output at ac recep-

tacles; weld output okay. Reset receptacle circuit breakers.

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

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, and the rotor.

Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (CC models) or field

current regulator board PC1 (CC/CV models) (see Section 9-7).

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

High output at generator power ac re-

ceptacles. Check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent adjust generator power field current resistor R3.

Low output at generator power ac recep-

tacles. Check engine speed, and adjust if necessary.

Check fuse F1, and replace if open (see Section 9-7). Have Factory Authorized Service Agent check inte-

grated rectifier SR1, resistor R3, and capacitor C9.

D. Optional Three-Phase Generator Power (CC/CV Models Only)

Trouble Remedy

No or low output at optional three-

phase generator/receptacle RC5. Place Process/Contactor switch in Electrode Hot - Stick position (see Section 7-3).

Reset circuit breaker CB7(see Section 8-2).

Reset circuit breaker CB5 (see Section 9-7).

Check engine weld/power speed, and adjust if necessary (see Section 9-5).

Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board

PC1.

High output at optional three−phase

generator/receptacle RC5. Check engine weld/power speed, and adjust if necessary (see Section 9-5).

Have Factory Authorized Service Agent check field current regulator board PC1.

Erratic output at optional three−phase

generator/receptacle RC5. Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board

PC1.

E. Engine

Trouble Remedy

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

Check battery connections and tighten if necessary.

Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-7).

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

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check Engine Control switch S1.

OM-491 Page 46 Return To Table Of Contents

Trouble Remedy

Engine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine.

Check fuel level.

Reset circuit breaker CB13 (see Section 9-7). Have Factory Authorized Service Agent check engine wir-

ing harness and components.

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

Have Factory Authorized Service Agent check control relay CR2, and fuel solenoid FS1.

Air in fuel system. See engine manual.

Engine starts, but stops when Magnetic

Shutdown switch is released. When starting engine, continue holding Magnetic Shutdown switch until after engine indicator lights go

out.

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

temperature is too high (see Sections 5-7 and 9-8).

Engine hard to start in cold weather. Use starting aid switch (see Section 6-1 or 7-1).

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 9-2).

Engine suddenly stops. Check fuel, oil, and coolant levels. Automatic shutdown system stops engine if fuel level or oil pressure

is too low, or coolant temperature is too high (see Sections 5-7 and 9-8).

See engine manual.

Engine slowly stopped and cannot be

restarted. Check fuel level.

Check engine air and fuel filters (see Sections 9-3 and 9-6).

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 (models with idle option

only).

Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1.

Check for obstructed throttle solenoid.

Engine does not run at idle speed

(models with idle option only). CC models: place Stick/TIG Selection switch in Stick position.

CC/CV models: place Process/Contactor switch in any position but Remote-TIG.

Check for obstructed throttle solenoid.

Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.

Engine uses oil during run-in period;

wetstacking occurs. Dry engine according to run-in procedure (see Section 11).

OM-491 Page 47Return To Table Of Contents

Notes

OM-491 Page 48 Return To Table Of Contents

SECTION 10 − ELECTRICAL DIAGRAMS

Figure 10-1. Circuit Diagram For CC Welding Generator

OM-491 Page 49Return To Table Of Contents

215 304-A

OM-491 Page 50 Return To Table Of Contents

Figure 10-2. Circuit Diagram For CC/CV Welding Generator

OM-491 Page 51Return To Table Of Contents

215 305-A

OM-491 Page 52 Return To Table Of Contents

SECTION 11 − RUN-IN PROCEDURE

run_in1 8/0

11-1. 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.

OM-491 Page 53Return To Table Of Contents

11-2. 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 A/V range switch in maxi-

mum position, A/V control in mini-

mum position, 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.

OM-491 Page 54 Return To Table Of Contents

11-3. 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 A/V range switch in maxi-

mum position, A/V control in mini-

mum position, 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.

OM-491 Page 55Return To Table Of Contents

SECTION 12 − 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

12-1. Selecting Equipment

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

1 Generator Power Receptacle

− 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.

Be sure equipment

has this symbol

and/or wording.

2-2. 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

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-491 Page 56 Return To Table Of Contents

12-3. 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.

12-4. 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 12-8).

3 Rating Data

Rating shows volts and amperes, or

watts required to run equipment.

VOLTS 115

4.5

AMPS

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-491 Page 57Return To Table Of Contents

12-5. 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

12-6. 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-491 Page 58 Return To Table Of Contents

12-7. 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-491 Page 59Return To Table Of Contents

12-8. 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

230 2.5

1/4

PHASE

CODE 60

AC MOTOR

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

12-9. 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.

OM-491 Page 60 Return To Table Of Contents

12-10. 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 12-4).

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

Welding

Generator

Output

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-491 Page 61Return To Table Of Contents

12-11. 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-491 Page 62 Return To Table Of Contents

SECTION 13 − PARTS LIST

Hardware is common and

not available unless listed.

13 14 15

2324

25 26 27

94 95

100

102

101 (CC ONLY)

104 FIG 13-2 OR 13-3)

105

106

107

108 (FIG 13-4 OR 13-5)

109

110 111

112 (FIG 13-7)

113

114

103 (CC ONLY)

116

Figure 13-1. Main Assembly

OM-491 Page 63

Return To Table Of Contents

802 265-G

114

115

Big Blue 502, 602 Only

38 39

41 42

46 (FIG 13-6) 47

49 50 51

54 55

59 60

6364 65

7172

73 74

83 84 85

86 87 8889

OM-491 Page 64 Return To Table Of Contents

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 13-1. Main Assembly

Quanti

1 189 824 PANEL, gen LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1♦199 294 PANEL, gen LH ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 191 626 BUMPER, door engine access 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 191 623 LABEL, warning all panels must be in place while running 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 199 592 LATCH, paddle series 20 (black) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 190 076 CHANNEL, stiffener engine access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5♦202 635 CHANNEL, stiffener engine access e-coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 190 992 KEEPER, latch engine access door 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 +200 989 DOOR, engine access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7♦+210 736 DOOR, engine access ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 190 518 LABEL, diesel engine maintenance perkins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 189 975 HINGE, door access 180deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 208 141 STOP, door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 189 826 PANEL, rocker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 ♦199 298 PANEL, rocker ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 190 190 TANK, coolant recovery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 Z1 189 395 REACTOR, ac 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 Z1 ♦201 520 REACTOR, ac environmental 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 1T 038 621 BLOCK, term 30A 4 pole frict term str 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038 620 LINK, jumper term blk 30A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 081 499 BRACKET, mtg strip terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 206 352 BRACE, front to center upright 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 SR4, SR5 035 704 RECTIFIER, integ bridge 40. amp 800v 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 CB4 045 061 CIRCUIT BREAKER, auto reset 24vdc 7 amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 T1 201 613 TRANSFORMER w/bracket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 T1 ♦205 636 TRANSFORMER, w/bracket (environmental coating) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 201 697 PAN, reactor and rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 173 352 EXTRUSION, rubber clamp/bulb (order by ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 189 708 FIREWALL, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 191 307 COVER, plate 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 190 182 PANEL, side air box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 189 763 BRACKET, mtg air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 189 764 AIR CLEANER, intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*192 938 FILTER, air element primary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*♦192 939 FILTER, air element safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 189 618 HOSE, air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 863 CLAMP, hose 1.125 − 3.000 clp dia 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 189 464 SEAL, weather lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173 909 HOSE, sae .312 id x .560 od x 24.000 (order by ft) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 201 658 UPRIGHT, center assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 191 819 HOSE, sae .312 id x .560 od x 14.000 (order by ft) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198 584 HOSE, sae .312 id x .560 od x 5.000 (order by ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 095 636 HOSE, sae .187 id x .41 od x 30.000 (order by ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 192 750 BASE, fuel filter w/adapter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 *192 744 FILTER, fuel spin-on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 192 741 BLOCK, spacer mtg filter base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 +201 934 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 ♦+202 640 COVER, top ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 189 052 GROMMET, plastic neck filler fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 190 198 CAP, tank screw-on 3.500 in w/vent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 192 041 LABEL, use diesel fuel only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 108 487 LABEL, warning falling equipment 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 176 230 LABEL, warning hot exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 105 734 PIPE, muffler extension elbow 1.750 od 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 201 851 COVER, radiator access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 ♦202 629 COVER, radiator access ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 191 354 SUPPORT, cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 ♦202 633 SUPPORT, cover e-coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-491 Page 65

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Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 13-1. Main Assembly (Continued)

Quanti

44 010 875 CLAMP, muffler 2.000 dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 193 314 MANIFOLD, exhaust muffler (Big Blue 402 only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 Figure 13-6 GENERATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 013 367 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 190 238 ENGINE, Perkins dsl elec 3.152 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*192 936 FILTER, oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*192 744 FILTER, fuel spin-on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*192 937 FILTER, fuel secondary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*195 615 SWITCH, coolant temperature 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*195 616 SWITCH, oil pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 ♦043 935 IDLE SOLENOID ASSEMBLY (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198 386 IDLE, Solenoid Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

085 963 SPRING, Ext .375 Od X .041 Wire X 2.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197 434 XFMR, Current Sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 *193 163 BELT, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 189 621 HOSE, radiator lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 189 622 HOSE, radiator upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 +201 976 GUARD, door 3.152 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 147 923 LABEL, warning moving parts can cause serious injury 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 +201 982 RADIATOR, w/shroud and 7# cap 3 row core (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

605 982 CAP, radiator pressure 7 lb 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 201 749 UPRIGHT, rear ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 ♦207 188 UPRIGHT, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦207 005 GRILL, rear panel ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 190 206 CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 108 081 TERMINAL PROTECTOR, battery post mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 190 207 CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 203 430 BRACKET, battery holddown 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 190 897 BATTERY, stor 12V 650crk 110rsv gp 24 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 201 006 BOLT, j stl .312−18 x 8.500 pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 +201 183 COVER, battery access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 ♦+202 639 COVER, battery access ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 168 385 LABEL, warning battery explosion can blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 201 996 LABEL, warning do not operate with guard missing 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 202 018 GUARD, perkins 3.152 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 +189 828 PANEL, engine side 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 ♦++199 301 PANEL, engine side ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 189 827 PANEL, gen RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 199 300 PANEL, gen RH ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 199 849 SCREW, 625-11 x 4.00hexhd pln gr 5 pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 071 731 WASHER, flat .656 ID x 2.250 OD x .187T stl pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 197 489 BRACKET, mtg RH Perkins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197 488 BRACKET, mtg LH Perkins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 071 890 RETAINER, mount eng/gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 071 730 TUBING, stl .875 OD x 12ga wall x 2.500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 083 476 MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 135 205 NUT, 625-11 .94hex .76H stl pld elastic stop nut 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 505 HOSE, oil drain assy 32 in (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 165 271 VALVE, oil drain 3/8-18NPTF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 176 529 FITTING, hose brs barbed fem 1/2tbg x 3/8NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 113 854 HOSE, SAE .500 ID x .780 OD xc oil (order by ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-491 Page 66 Return To Table Of Contents

Description

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Dia.

Mkgs.

Item

No.

Figure 13-1. Main Assembly (Continued)

Quanti

79 191 610 FITTING, hose stl elbow .500tbg x 3/4-16 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 190 180 WASHER, flat .750 ID x 1.250 OD x .125T stl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 191 499 LINE, fuel return 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191 608 FITTING, cprsn brs nut 1/4tbg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191 606 FITTING, cprsn brs sleeve 1/4tbg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 191 500 LINE, fuel supply 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 189 245 TANK, fuel 23gal (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 124 253 BUSHING, tank fuel 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

084 173 CLAMP, hose .460 − .545clp dia slfttng 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 189 912 FITTING, stl barbed elbow w/.047 in orf zinc pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 189 909 FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 201 025 CAP, fuel fitting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 189 913 FITTING, stl barbed elbow zinc pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 190 142 SENDER, fuel gauge 9.7500 deep tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 189 910 FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91 189 908 VALVE, drain fuel 180deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 181 572 BUSHING, tank fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 191 446 EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) 6ft. . . . . . . . . . . . . . . . . . . . . . . . . .

94 190 250 LABEL, warning do not weld on base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 191 897 BRACKET, mtg unit 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96 192 362 BRACKET, mtg nyl 1/2 conduit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 196 220 BRACKET, hold down fuel tank rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98 +200 999 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98 ♦+203 382 BASE e-coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 191 512 BRACKET, hold down fuel tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 190 179 PANEL, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 R4 CC191 292 RESISTOR, WW fxd 375W 50 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 R3 189 699 RESISTOR, WW tap 375W 10 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 R2 CC189 699 RESISTOR, WW tap 375W 10 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 Figure 13-2, 13-3 CONTROL BOX ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105 189 731 FIREWALL, lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106 +201 750 UPRIGHT, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106 ♦+202 637 UPRIGHT, front ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107 182 761 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108 13-4, 13-5 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109 ♦202 130 XFMR, current sensing (auto idle option) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110 190 010 LABEL, warning do not use ether 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111 191 448 TOP, cover front upright 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111 ♦199 305 TOP, cover front upright ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112 Figure 13-7 MAIN RECTIFIER ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 CV193 453 BRACKET, mtg box fcr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 PC1 CV189 143 MODULE, field current regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 189 535 PIPE, exhaust (Big Blue 502 and 602 only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115 105 740 MUFFLER, exhaust engine 1.925 inlet/outlet (Big Blue 502 & 602 only) 1. . . . . . . . . . . . . . . . .

116 212 944 LABEL, CC Stick Overlap Weld Ranges 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 058 NUT, .250-20 u-nut multi-thread 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049 525 NUT, 312-18 u-nut multi-thread 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202 021 KIT, label (includes safety and informational labels) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 202 021.

*Recommended Spare Parts.

CCCC models only.

CVCC/CV models only.

♦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-491 Page 67

Return To Table Of Contents

802 551-E

Figure 13-2. Control Box Assembly − CC Models

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure13-2. Control Box Assembly − CC Models (Figure 13-1 Item 104)

Quanti

1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 046 432 HOLDER, fuse mintr .250 x 1.250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 201 077 CONTROL BOX, lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 201 078 CONTROL BOX, rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 201 079 COVER, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 C12 191 944 CAPACITOR, polyp met film 10. uf 250 vac 10% 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 681 HARNESS, control box, weld control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 CR7 188 636 RELAY, OCV control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 D1/C1 189 701 DIODE/CAPACITOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 SR1, SR2 035 704 RECTIFIER, integ 40A 800V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CR5 090 104 RELAY, encl 12VDC SPST 30A/15VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S5 011 609 SWITCH, tgl spdt 15a 125vac on−none−on spd term chr. . . . . . . . . . . . . . . . . . . . (located on front panel, see 13-4) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S6 011 622 SWITCH, tgl 3pdt 15a 125vac on−none−on spd term. . . . . . . . . . . . . . . . . . . . (located on front panel, see 13-4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC4 047 483 CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . . . . .

RC3 158 466 CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . . . . .

RC1 135 133 CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177 859 CONN, body 5 terminal (to engine control switch S1) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 316 CONN, rect univ 039 6p/s 3row plug cable lkg 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

092 670 CONN, rect univ 084 3p/s 1row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 CB11, 12, 13 139 266 CIRCUIT BREAKER, man reset 1P 15A 250VAC frict 3. . . . . . . . . . . . . . . . . . . . .

OM-491 Page 68 Return To Table Of Contents

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 13-2. Control Box Assembly − CC Models (Continued)

Quanti

190 260 HARNESS, unit weld control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 158465 CONN, rect univ 084 12p/s 3row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187654 SEAL, wire univ 12p/s 3row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 114063 CONN, rect univ 084 4p/s 1row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192309 CLIP, snap in .630 bundle .250 hole .248 thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 177 136 CLAMP, capacitor 1.375dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 C9 087 110 CAPACITOR, elctlt 240uf 200VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 R6 141 424 RESISTOR, ww fxd 30 w 25 ohm faston te 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 PC7 ♦195706 MODULE, pull to idle, two output, 7 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 CR4 ♦113247 RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 CR6 ♦090104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 CR2, CR3 090 104 RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg 2. . . . . . . . . . . . . . . . . . . . . .

205 970 HARNESS, engine control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 R8 214 863 RESISTOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 CB10 190 374 CIRCUIT BREAKER, auto reset 12VDC 40A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 CR1 214 876 RELAY, Encl 6vdc Spst 35a/14vdc 5 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 114 062 CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185 655 SEAL, wire univ 15P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 CR8 155 309 CONTACTOR, solenoid 12VDC cont 400A inrush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional

*Recommended Spare Parts.

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.

802 360-D

Figure 13-3. Control Box Assembly − CC/CV Models

OM-491 Page 69

Return To Table Of Contents

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 104)

Quanti

1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 046 432 HOLDER, fuse mintr .250 x 1.250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 201 077 CONTROL BOX, lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 201 078 CONTROL BOX, rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 201 079 COVER, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 134 201 STAND-OFF, support pc card 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PC9 192 224 CIRCUIT CARD ASSY, display 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 C9 087 110 CAPACITOR, elctlt 240uf 200VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 177 136 CLAMP, capacitor 1.375dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 495 HARNESS, control box, cv weld control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 SR1 035 704 RECTIFIER, integ 40A 800V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 CR5 090 104 RELAY, encl 12VDC SPST 30A/15VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC4 047 483 CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . . . . .

RC3 158 466 CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . . . . .

RC1 135 133 CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . . . . . .

12 CB11, 12, 13 139 266 CIRCUIT BREAKER, man reset 1P 15A 250VAC frict 3. . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S6 193 324 SWITCH, rotary 6 position gold contacts. . . . . . . . . . . . . . . . . . . (located on front panel, see 13-5) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S5 011 609 SWITCH,tgl spdt 15a 125vac on−none−on spd term chr. . . . . . . . . . . . . . . . . . . . (located on front panel, see 13-5) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 316 CONN, rect univ 039 6p/s 3row plug cable lkg 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177 859 CONN, body 5 terminal (to engine control switch S1) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 183 CONN, rect cinch 18 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196 602 PLUG, cavity 18,30 position cinch connector 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196 603 SEAL, switch 6 position rotary .250 shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141 450 CONN, rect metrmate 10skt 1row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 PC7 ♦195 706 MODULE, pull to idle, two output, 7 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CR4 ♦113 247 RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CR6 ♦090104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 CR2, CR3 090 104 RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg 2. . . . . . . . . . . . . . . . . . . . . .

205 970 HARNESS, engine control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 R8 189 701 RESISTOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 CB10 190 374 CIRCUIT BREAKER, auto reset 12VDC 40A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 CR1 214 876 RELAY, Encl 6vdc Spst 35a/14vdc 5 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 114 062 CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185 655 SEAL, wire univ 15P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 CR8 155 309 CONTACTOR, solenoid 12VDC cont 400A inrush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional

*Recommended Spare Parts.

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-491 Page 70 Return To Table Of Contents

Hardware is common and

not available unless listed.

802 266-D

Figure 13-4. Panel, Front w/Components − CC Models

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 108)

Quanti

1 202 705 PLATE SCREENED, ident control rating; when ordering this item,. . . . . . . . . . . . . . . . . . the nameplate should also be ordered) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 NAMEPLATE, screened (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 201 580 PANEL, engine/weld control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3♦202 642 PANEL, engine/weld control ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S3 189 382 SWITCH, range/changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦202 223 BUS BAR, idealized 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 558 HARNESS, range (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC6 148 439 HOUSING, rect univ 084 4p/s 1 row rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R1 188 635 RHEOSTAT, WW 300W 34 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 202 209 SPACER, nylon 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 S6 011 622 SWITCH, tgl DPDT 15A 125VAC (included in control box harness,. . . . . . . . . . . . . . . see 13-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-491 Page 71

Return To Table Of Contents

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 13-4. Panel, Front w/Components − CC Models (Continued)

Quanti

8 S5 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in. . . . . . . . . . . . . . . control box harness, see 13-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 RC13 032 897 RECEPTACLE, twlk grd 2P3W 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 S1 176 606 SWITCH, ignition 4posn w/o handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 S2 021 467 SWITCH, tgl spst 3a 250v off−none−(on) spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 MS1 189 698 SWITCH, magnetic manual reset low current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 553 CLIP, circuit breaker retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CB1 201 083 CIRCUIT BREAKER, man reset 2P 20 A, 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 109 HARNESS, generator power (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CB2 093 996 CIRCUIT BREAKER, man reset 1P 20A 250VAC frict 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 GFCI1 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

16 RC1 147 632 RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 190 861 LABEL, warning electric shock and moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 +201 106 PANEL, gen pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 ♦+202 641 PANEL, gen pwr ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 ♦+210 750 PANEL, gen pwr ss CE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 083 030 STUD, brs .250−20 x 1.750 w/hex collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 601 836 NUT, 250−20 .50hex .19h brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 ♦196 073 LABEL, do not switch while welding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 S12 ♦195 825 SWITCH, polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 201 125 PANEL, mtg terminal pwr output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 ♦199 303 PANEL, mtg terminal pwr output ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 735 WASHER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 181 169 SPACER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 186 621 BOOT, generic output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 ♦059 773 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 ♦010 647 PIN, spring cs .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 193 260 COVER, receptacle 2.250 dia lexan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 193 258 COVER, receptacle GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 190 323 BOOT, circuit breaker clear hex nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 193 143 BOOT, magnetic shutdown switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 021 385 BOOT, toggle switch lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 119 014 LEVER, switch black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 PL1 191 241 LED, red 12V 4 ind lights panel mtg round 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 FUEL 191 242 GAUGE, fuel elec switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 HM 118 058 METER, hour 12-24VDC 2.25dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 ♦193 228 METER, Volt Dc 8− 18 Scale 2.250 In Black Face 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 ♦193 229 GAUGE, Coolant Temp 0− 300 Deg F Electric Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦193 231 SENDER, Coolant Temp 300 Deg F 1/2−14 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 ♦193 227 GAUGE, Pressure Oil 0−100 Psi Electric Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦193 230 SENDER, Pressure Oil 0− 100 Psi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 ♦194 348 AMMETER, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦030 084 SHUNT, Meter 50mv 600 Amp Lt Wt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 ♦194 345 VOLT METER, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 189 161 HANDLE, switch range 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 010 647 PIN, spring CS .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 019 602 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

024 103 BLANK, snap−in nyl .750 mtg hole black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 202 021.

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-491 Page 72 Return To Table Of Contents

Hardware is common and

not available unless listed.

802 332-F

19 20 21

15 16

41 40 39 38

Figure 13-5. Panel, Front w/Components − CC/CV Models

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 108)

Quanti

1 202 706 PLATE SCREENED, ident control; when ordering this item,. . . . . . . . . . . . . . . . . . the nameplate should also be ordered) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 NAMEPLATE, screened (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 201 580 PANEL, engine/weld control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3♦202 642 PANEL, engine/weld control ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S3 189 382 SWITCH, range/changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦202223 BUS BAR, idealized 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 558 HARNESS, range (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC6 148 439 HOUSING, rect univ 084 4p/s 1 row rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-491 Page 73

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Description

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Dia.

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Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)

Quanti

5 R1 193 118 POT, cp flat 1t 2w 1k ohm linear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 S6 193 234 SWITCH, rotary 6 position gold contacts (included in control box harness,. . . . . . . . . . . . . . see 13-3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 S5 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in. . . . . . . . . . . . . . . control box harness, see 13-3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 202 209 SPACER, nylon 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PC6 192 995 CIRCUIT CARD ASSY, connector/receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CB5 139 266 CIRCUIT BREAKER, man reset 1p 15a 250vac frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 S1 176 606 SWITCH, ignition 4posn w/o handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 S2 021 467 SWITCH, tgl spst 3a 250v off−none−(on) spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 MS1 189 698 SWITCH, magnetic manual reset low current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CB1 201 083 CIRCUIT BREAKER, man reset 2P 20 A, 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 553 CLIP, circuit breaker retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 109 HARNESS, generator power (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CB2 093 996 CIRCUIT BREAKER, man reset 1P 20A 250VAC frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 GFCI1 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

17 RC1 147 632 RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 RC5 ♦182 954 RCPT, str 3P4W 50A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 ♦025 248 STAND-OFF, insul .250-20 x 1.2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 ♦604 102 CONNECTOR, clamp cable 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 ♦197 527 GUARD, circuit breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 ♦197 363 TERMINAL, ring tng screw clamp 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 CB7 ♦196 780 CIRCUIT BREAKER, man reset 3p 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 +201 106 PANEL, generator power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 ♦202 641 PANEL, generator power ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 +♦201 107 PANEL, generator power (full kVA option) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 ♦196 781 BOOT, circuit breaker 3 pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 ♦197 508 PLUG, protective 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 ♦077 440 BUSHING, conduit 1 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 601 836 NUT, 250−20 .50hex .19h brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 ♦197 291 COVER, receptacle w/gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 083 030 STUD, brs .250−20 x 1.750 w/hex collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CT2 ♦197 433 TRANSFORMER, current sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 190 861 LABEL, warning electric shock and moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 ♦197 399 LABEL, warning 3 ph generator power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 193 260 COVER, receptacle 2.250 dia lexan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 193 258 COVER, receptacle GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 190 323 BOOT, circuit breaker clear hex nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 S12 ♦195 825 SWITCH, polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 201 125 PANEL, mtg terminal pwr output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 199 303 PANEL, mtg terminal pwr output ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 PC4, PC5 189 744 CIRCUIT CARD ASSEMBLY, filter hf 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 735 WASHER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 134 201 STAND-OFF, support 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 181 169 SPACER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 186 621 BOOT, generic output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 ♦059 773 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 ♦010 647 PIN, spring cs .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 ♦196 073 LABEL, do not switch while welding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 193 143 BOOT, magnetic shutdown switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 021 385 BOOT, toggle switch lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 119 014 LEVER, switch black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 190 323 BOOT, circuit breaker clear hex nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 170 391 CONN, circ ms protective cap size 20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 PL1 191 241 LED, red 12V 4 ind lights panel mtg round 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-491 Page 74 Return To Table Of Contents

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Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)

Quanti

52 FUEL 191 242 GAUGE, fuel elec switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 HM 118 058 METER, hour 12-24VDC 2.25dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 ♦193 228 METER, Volt Dc 8− 18 Scale 2.250 In Black Face 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 ♦193 229 GAUGE, Coolant Temp 0− 300 Deg F Electric Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦193 231 SENDER, Coolant Temp 300 Deg F 1/2−14 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 ♦193 227 GAUGE, Pressure Oil 0−100 Psi Electric Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦193 230 SENDER, Pressure Oil 0− 100 Psi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 ♦194 348 AMMETER, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦030 084 SHUNT, Meter 50mv 600 Amp Lt Wt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 ♦194 345 VOLT METER, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 097 922 KNOB, pointer .875 dia x .250 ID w/set screws plstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 189 161 HANDLE, switch range 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 010 647 PIN, spring CS .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 097 924 KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 CB6 083 432 CIRCUIT BREAKER, Man Reset 1p 10a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 158 HARNESS, unit weld control − CV (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 114 063 CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8 193 184 CONNECTOR, rect cinch 30 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG13 147 992 CONNECTOR, rect univ 039 10p/s 2 row plug cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 158 465 CONNECTOR, rect univ 084 12p/s 3 row plug cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

088 731 BUSHING, snap-in nyl .375 ID x .500 mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135 873 CLIP, conduit convoluted 1/2 in mtg hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 654 SEAL, wire univ 12p/s 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

024 103 BLANK, snap-in nyl .750 mtg hole blk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 304 BLANK, snap−in nyl .250 mtg hole black 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 202 021.

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.

Hardware is common and

not available unless listed.

802 267-B

1516

Figure 13-6. Generator

OM-491 Page 75

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Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 13-6. Generator (Figure 13-1 Item 46)

Quanti

1 132 053 SCREW, 375-16 x 1.50hexhd pln gr 5pld 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 183 387 WASHER, conical spring .406 ID x .875 OD pltd 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 195 911 ENDBELL, gen (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 143 220 O-RING, 2.859 ID x .139CS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 201 099 STATOR, exciter/gen pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 +208 287 STATOR, weld assembly complete 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6+♦209 220 STATOR, weld assembly complete (full kVA option) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 013 367 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 190 197 GUARD, generator wire mesh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 172 674 SPRING, ext .240 OD x .041 wire x 3.500pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 191 580 COVER, starter hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 191 576 GUARD, starter Perkins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 039 207 BAFFLE, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 ROTOR 212 997 ROTOR, Generator Segmented Assy (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 210 446 ROTOR, Generator (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 024 617 RING, Rtng Ext 1.375 Shaft X .050 Thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 053 390 BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X .6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HUB, Drive (Not Sold Separately) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210 447 FAN, Rotor Assy Generator (Segmented) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 210 332 PLATE, Flex Hubmount 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 206 242 FAN, Rotor Segmented Assy Gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 049 026 SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 080 389 SCREW, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 049 026 SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 191 579 COVER, starter hole Perkins/Continental 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 172 555 SCREW, M10-1.5 x 50hexhd pln 8.8pld 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 602 159 SCREW, .312-18 X .75hexwhd 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 601 961 SCREW, .312-18 x 2.25hexhd pln gr 5pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 602 211 WASHER, lock .318 ID x 0.586 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 139 341 WASHER, exciter 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 *190 823 BRUSH, contact 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 208 469 CLIP, spring 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 189 142 BRUSHHOLDER ASSEMBLY, gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 602 242 WASHER, flat .375idx0.875odx.083t stl pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 602 211 WASHER, Lock .318idx0.586odx.078t Stl Pld Split.312 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 604 534 SCREW, 312−18X1.25 hex hd−pln gr5 pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 259 HARNESS, brush (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 168 071 CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . .

187 651 SEAL, wire univ 9P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 202 021.

*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-491 Page 76 Return To Table Of Contents

Hardware is common and

not available unless listed.

802 279-A

Figure 13-7. Main Rectifier Assembly

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 13-7. Main Rectifier Assembly (Figure 13-1 Item 111)

Quanti

SR3 201 747 RECTIFIER (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SR3 ♦203 381 RECTIFIER, environmental (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 188 137 CONNECTION BOARD, rectifier AC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 188 517 BUS BAR, connection board 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 188 135 ENCLOSURE, rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 134 201 STAND-OFF, support 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PC3 201 449 CIRCUIT CARD ASSEMBLY, protection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 188 136 INSULATOR, heat sink 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 188 493 HEAT SINK, rectifier al 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 D3, D5, D7 208 334 DIODE, rect 275A 300V SP 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 D2, D4, D6 208 335 DIODE, rect 275A 300V RP 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

Warranty Questions?

Call

1-800-4-A-MILLER

for your local

Miller distributor.

miller_warr 8/03

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, 2003

(Equipment with a serial number preface of “LC” 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

* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Supplies

* Intellitig

* Maxstar 150

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by

the engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* DS-2 Wire Feeder

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

* Process Controllers

* Positioners and Controllers

* Automatic Motion Devices

* RFCS Foot Controls

* Induction Heating Power Sources

* Water Coolant Systems

* Flowgauge and Flowmeter Regulators (No Labor)

* HF Units

* Grids

* Maxstar 85, 140

* Spot Welders

* Load Banks

* 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.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches

* Induction Heating Coils and Blankets

* 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  2003 Miller Electric Mfg. Co. 1/03

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.

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com

to locate 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:

Miller Electric Big Blue 402P Users Manual O491ap_mil

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