Miller Big Blue 251D Owner`s manual

OM-480
128 576AA
October 2002
Processes
Stick (SMAW) Welding
Air Carbon Arc (CAC-A)
Cutting And Gouging
With Optional Equipment:
Flux Cored (FCAW) With
Voltage-Sensing Wire Feeder
Description
Engine Driven Welding Generator

Big Blue 251D
Visit our website at
www.MillerWelds.com
From Miller to You
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
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
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 orindividual 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.
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
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.)
WARNING
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.
CALIFORNIA
Proposition 65
Warning
Diesel engine exhaust and
some of its constituents
are known to the State of
California to cause
cancer, birth defects, and
other reproductive harm.
The following terms are
used interchangeably
throughout this manual:
Stick = SMAW
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. AC Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Optional AC Power Plant Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Installing Muffler Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Installing Ether Cylinder (Optional Ether Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Selecting Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – Operating the Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Remote A/V Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. 120 Volt Duplex And Optional GFCI Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. 240 Volt Duplex Receptacle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Connecting Optional Auxiliary Power Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. 120/240 Volt Twistlock Receptacle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Servicing Optional Ether Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Inspecting And Cleaning Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 – RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 – AUXILIARY POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
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SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING
rom _nd_10/02
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 Standards listed in Section 1-6. Read and follow all
Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
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.
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 electrically 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 presented: 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 separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another 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 worktable 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
stopping engine.
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
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
an3 air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
OM-480 Page 1
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.
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.
ARC RAYS can burn eyes and skin.
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.
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.
WELDING can cause fire or explosion.
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.
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, cuffless 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.
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 operations.
CYLINDERS can explode if damaged.
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.
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 designed 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
3
BATTERY EXPLOSION can BLIND.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables or servicing battery.
DoPage
not allow
tools to cause sparks when working on a battery.
OM-480
2
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and –) on batteries.
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding 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.
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
components.
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
present 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.
ENGINE EXHAUST GASES can kill.
Use equipment outside in open, well-ventilated
areas.
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
flammables.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
Turn cap slightly and let pressure escape slowly before
completely removing cap.
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.
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.
COMPRESSED AIR can cause injury.
HOT PARTS can cause burns and injury.
Wear approved safety goggles.
Do not direct air stream toward self or others.
Do not touch hot compressor or air system
parts.
Let system cool down before touching or
servicing.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
Release air pressure from tools and system
before servicing, adding or changing attachments, or opening compressor oil drain or oil
fill cap.
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
stopping 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.
OM-480 Page 3
FLYING SPARKS can cause injury.
H.F. RADIATION can cause interference.
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.
ARC WELDING can cause interference.
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
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) manuals.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications 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.
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
electromagnetically 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. 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 Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
National Electrical Code, NFPA Standard 70, 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).
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 Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent 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).
1-7. 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 electromagnetic 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 powerfrequency 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.
OM-480 Page 4
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.
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT
UTILISATION
rom _nd_fre 4/02
1-1. 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 signifie 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-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-5. 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.
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 composants.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
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.
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.
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.
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 isolants 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 nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
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 endommagé 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.
Porter un casque de soudage muni d’un écran de filtre approprié pour protéger 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, résistant au feu (laine ou cuir) et une protection des pieds.
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 instructions 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 portant un respirateur à alimentation d’air. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent 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 dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, 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-480 Page 5
LE SOUDAGE peut provoquer un incendie ou une explosion.
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, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
Prévoir une période de refroidissement avant d’effectuer 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.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
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 endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec
précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, 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 bouteille.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
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 déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés
correctement conformément à AWS F4.1 (voir les normes de sécurité).
Brancher le câble sur la pièce le plus près possible de la zone de soudage
pour éviter le transport du courant sur une longue distance par des chemins 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-électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des gants
en cuir, une chemise en matériau lourd, des pantalons sans revers, des
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.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
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.
1-3. Dangers existant en relation avec le moteur
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
OM-480 Page 6
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’expansion (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
suivant :
Mettre des lunettes de sécurité et des gants, placer un torchon sur le
bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
DES ORGANES MOBILES peuvent
provoquer des blessures.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas approcher les mains des ventilateurs, courroies 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’entretien et de dépannage.
Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, débrancher le câble négatif (–) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles.
Remettre en place les panneaux ou les 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.
L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.
Toujours porter une protection faciale, des gants en
caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher les câbles de
batterie.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide.
Observer la polarité correcte (+ et –) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier
lieu.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
LES GAZ D’ÈCHAPPEMENT DU
MOTEUR peuvent provoquer des
accidents mortels.
Utiliser l’équipement à l’extérieur dans des zones ouvertes et bien ventilées.
En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappement du moteur vers l’extérieur à distance des entrées d’air dans les bâtiments.
LA CHALEUR DU MOTEUR peut provoquer 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.
1-4. 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.
LES ÉTINCELLES VOLANTES risquent 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 protecteurs. 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.
LES CHARGES ÉLECTROSTATIQUES 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.
LE SURCHAUFFEMENT peut endommager le moteur électrique.
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.
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.
Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur.
Ne pas laisser tourner le moteur trop lentement sous
risque d’endommager le moteur électrique à cause
d’une tension et d’une fréquence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a
lieu.
LIRE LES INSTRUCTIONS.
Utiliser seulement les pièces de rechange d’origine.
Effecteur la maintenance et la mise en service
d’après le manuel et celui du moteur.
OM-480 Page 7
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LE SOUDAGE À L’ARC 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 qualifié 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.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement commandé 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 soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que
le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
1-5. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
OM-480 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
SECTION 2 – DEFINITIONS
2-1. Symbols And Definitions
A
Stop Engine
Fast (Run, Weld/
Power)
Slow (Idle)
Start Engine
Fast/Slow
(Run/Idle)
Battery (Engine)
Circuit Breaker
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
Panel/Local
Remote
Engine
Temperature
Output
Time
Hours
Seconds
V
Amperes
Read Operator’s
Manual
G
1
Alternating
Current
Do Not Switch
While Welding
1
Single Phase
h
3
Three Phase
s
Ether Starting Aid
Engine Coolant
Temperature
OM-480 Page 9
SECTION 3 – SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Rated Welding
Output
Amperage
Range
250 A,
40 Volts DC,
100% Duty Cycle
Maximum
Open-Circuit
Voltage DC
(Nominal)
40 – 400
Generator Power
Rating
Single-Phase,
3 kVA/kW, 26 A,
120 V AC, 60 Hz
95 (90)
Engine
Fuel Capacity
Deutz F3L-1011
Air/Oil-Cooled,
Three-Cylinder,
29 HP Diesel Engine
11.3 gal (42.8 L)
3-2. Dimensions, Weights, And Operating Angles
Dimensions
Height
40-1/2 in (1029 mm)
Width
24-5/8 in (625 mm)
Depth
56 in (1422 mm)
A
23-1/4 in (591 mm)
B
24-5/8 in (625 mm)
C
11/16 in (17 mm)
D
2-7/8 in (73 mm)
E
4-1/2 in (114) mm)
F
22-9/16 in (573 mm)
G
27 in (686 mm)
H
30-3/8 in (772 mm)
J
41-1/4 in (1048 mm)
K
51-1/8 in (1299 mm)
N
Do not exceed tilt angles or engine
could be damaged or unit could tip.
M
L
K
J
H
30°
G
M
F
D
30°
E
A
54 in (1372 mm)
M
21/32 in (16.7 mm) Dia.
4 Holes
N
1/2 in (12.7 mm) Dia.
10 Holes
Weight
1475 lb (670 kg)
OM-480 Page 10
30°
30°
C
B
angles 4/96
Ref. 110 850-F
L
Do not move or operate unit where it
could tip.
3-3. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
SB-137 487-A
3-4. Duty Cycle And Overheating
100% Duty Cycle At 250 Amperes
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
rduty1 5/95 – SB-070 999-B
OM-480 Page 11
3-5. AC Generator Power
The ac power curve shows the generator power in amperes available
at the 120 and 240 volt receptacles.
300
125
250
100
200
75
150
50
100
25
50
AC VOLTS
150
0
0
0
5
10
15
20
25
30
AC AMPERES IN 240V MODE
10
0
20
30
40
50
60
AC AMPERES IN 120V MODE
rsb3.1 2/92 – 206 031
3-6. Volt-Ampere Curves
100
RANGES:
VOLTS
80
MIN – 80
65 – 120
95 – 200
160 – 330
200 – MAX
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.
60
40
20
0
0
100
200
300
400
500
600
700
AMPERES
206 033
OM-480 Page 12
3-7. Optional AC Power Plant Curves
The ac power curves show the generator power in amperes available
at the single-phase 120/240 volt or
three-phase 240 volt terminals.
A. 7.5 KVA/KW Single-Phase AC Power Plant (No Weld Load)
B. 10 KVA/KW Three-Phase AC Power Plant (No Weld Load)
280
AC VOLTS
260
240
220
200
180
0
10
20
30
40
50
60
70
AC AMPERES
rsb13.1 12/94 - 134 636-A / 206 032
OM-480 Page 13
SECTION 4 – INSTALLATION
4-1. Installing Welding Generator
Movement
Airflow Clearance
Location
18 in
(460 mm)
Do Not Lift Unit From End
18 in
(460 mm)
18 in
(460 mm)
OR
OR
18 in
(460 mm)
18 in
(460 mm)
Always securely fasten welding
generator onto transport vehicle
or trailer and comply with all DOT
and other applicable codes.
Grounding
1
2
Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
GND/PE
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
1
Electrically bond generator frame to
vehicle frame by metal-to-metal
contact.
2
3
3
Equipment Grounding Terminal (On
Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Connect cable from equipment ground
terminal to metal vehicle frame. Use #10
AWG or larger insulated copper wire.
install1 7/02 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
4-2. Connecting The Battery
Connect Negative (–)
Cable Last.
–
+
Tools Needed:
1/2 in
OM-480 Page 14
156 011-A / Ref. 206 029 / S-0756
4-3. Installing Muffler Pipe
Stop engine and let cool.
Do not blow exhaust toward
air cleaner or air intake.
Top View
Tools Needed:
1/2 in
exh_pipe2 12/96 – 154 089-A / 154 611 / Ref. 206 029
4-4. Engine Prestart Checks
Check all fluids daily. Engine must be
cold and on a level surface.
Follow run-in procedure in engine
manual. If unburned fuel and oil collect in exhaust pipe during run-in, see
Section 9.
Fuel
1/2 in
(13 mm)
Do not use gasoline. Gasoline
will damage engine.
Full
Add fresh diesel fuel before starting
engine the first time (see maintenance label for specifications). Fill
fuel tank up to 1/2 in. (13 mm) from top
to allow room for expansion. Open
fuel shut-off valve.
Diesel
Do not run out of fuel or air enters fuel
system and causes starting problems. See engine manual to bleed air
from fuel system.
Oil
After fueling, check oil with unit on level surface. If oil is not up to full mark on
dipstick, add oil (see maintenance label).
Your unit may have the optional
low oil pressure shutdown
switch. However, some conditions 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.
Valve Open
To improve cold weather starting:
Full
Keep battery in good condition.
Store battery in warm area off
concrete 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.
Ref. 800 159-D
OM-480 Page 15
4-5. Installing Ether Cylinder (Optional Ether Starting Aid)
Stop engine.
Improper handling or exposure to ether can harm your
health. Follow manufacturer’s safety instructions on
cylinder.
1
Do not use Ether Starting Aid
while engine is running.
Open side door(s).
1
Ether Cylinder
2
Nozzle
Remove cover and clean cylinder
nozzle.
2
3
3
Clamp
4
Fitting
5
Cap
6
Valve
Remove cap and clean fitting.
Install cylinder on fitting. Tighten
clamp.
4
5
After installing cylinder, wait at
least 10 minutes before using
to let ether particles settle and
prevent atomizer plugging.
6
Put cap on fitting when cylinder is
removed.
ether1 12/96 – 153 382-A / Ref. 206 029
4-6. Connecting To Weld Output Terminals
Open left side door.
1
Bracket
Route cables through bracket.
2
Positive (+) Weld Output
Terminal
3
Negative (–) Weld Output Terminal
For Stick welding Direct Current
Electrode Positive (DCEP), connect work cable to (–) terminal and
electrode holder cable to (+)
terminal.
3
For Direct Current Electrode Negative (DCEN), reverse cable
connections.
2
If equipped with optional polarity
switch, connect electrode holder
cable to Electrode (–) terminal and
work cable to Work (+) terminal.
For FCAW welding, connect work
cable to (–) terminal and wire feeder
cable to (+) terminal.
1
Close door.
Tools Needed:
3/4 in
OM-480 Page 16
Ref. 800 162-A
4-7. 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
400 ft
(105 m) (120 m)
Weld Output
Terminals
Turn off power before
connecting to weld output terminals.
Welding
Amperes
10 – 60%
Duty
Cycle
60 – 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)
Do not use worn, damaged, undersized, or
poorly spliced cables.
10 – 100% Duty Cycle
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (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-480 Page 17
SECTION 5 – OPERATING THE WELDING GENERATOR
5-1. Controls (See Section 5-2)
1
2
3
13
4
12
11
10
9
8
7
6
5
15
14
Ref. 206 029 / 800 162-A / 800 159-D
OM-480 Page 18
5-2. Description Of Front Panel Controls (See Section 5-1)
This unit has a max OCV control circuit
that resets the Amperage/Voltage Control to maximum when the arc breaks.
When an arc is struck, weld output control
returns to the front panel or remote control setting. The Amperage/voltage Control adjusts amperage only when welding
and does not adjust open-circuit voltage.
1 Ampere Range Switch
Use switch to select weld amperage range.
For most welding applications, use lowest
amperage range possible to prevent arc outages.
Do not switch under load.
2 Amperage/Voltage Control
Control adjusts amperage within range
selected by Ampere Range switch. Weld output would be 148 A DC with controls set as
shown (50% of 95 to 200 A).
3 DC Voltmeter (Optional)
4 DC Ammeter (Optional)
5 Remote A/V Switch And Receptacle
(See Section 5-3)
6 Magnetic Shutdown Switch (Optional)
Use switch during start-up to bypass optional
engine shutdown system. System stops engine if oil pressure is too low or oil temperature
is too high.
7 Engine Control Switch
To Start: turn switch to Start while pressing
Shutdown switch. Release switches when
engine starts.
If the engine does not start, let engine
come to a complete stop before attempting restart.
In Run position, engine runs at weld/power
speed. In Run/Idle position (optional), engine
runs at idle speed at no load and weld/power
speed with load applied.
To Stop: turn switch to Off position.
8 Battery Charging Warning Light
Light goes on when battery is not charging.
9 Oil Pressure Warning Light
Light goes on if oil pressure is too low. If unit
has automatic shutdown option, light also
goes on if oil temperature is too high.
Stop engine and fix trouble if either
light goes on.
10 Ether Starting Aid Switch (Optional)
Push switch up and release while cranking
engine to release ether.
Do not use Ether if engine is running.
11 Engine Hour Meter
12 Oil Temperature Gauge/Switch
(Optional)
13 Oil Pressure Gauge/Switch (Optional)
14 Polarity Switch (Optional)
Place switch in Straight position for electrode
negative, or Reverse position for electrode
positive.
15 Manual Shutoff Lever
Use lever to stop engine if engine control
switch does not work.
5-3. Remote A/V Control
1
A/V Control Switch
Use switch to select front panel or
remote amperage control.
2
1
2
Example: Combination Remote Amperage Control
Remote A/V Receptacle RC3
Connect optional remote control to
RC3.
In Example:
Range = 95 to 200 A
Percentage Of Range = 50%
Max = 148 A DC (50% of 95 to 200)
Max (148 A DC)
Min (70 A DC)
Set Switch
Set Range
Set Percentage
Adjust Optional Remote Control
S-0774
OM-480 Page 19
SECTION 6 – OPERATING AUXILIARY EQUIPMENT
6-1. 120 Volt Duplex And Optional GFCI Receptacles
1
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
2
1
120 V 15 A AC Receptacle
RC1
2
120 V 15 A AC Receptacle
RC2
3
120 V 20 A AC GFCI
Receptacles GFCI1 And
GFCI2 (Optional)
Receptacles supply 60 Hz singlephase power at weld/power speed.
4
Circuit Breakers CB1 And
CB2
CB1 protects RC1/GFCI1 and CB2
protects RC2/GFCI2 from overload. If CB1 or CB2 opens, the
receptacle does not work.
If a circuit breaker continues to
open, contact Factory Authorized Service Agent.
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.
At least once a month, run en-
4
gine at weld/power speed and
press test button to verify GFCI
is working properly.
3
Maximum output from each duplex
receptacle is 1.8 kVA/kW, and 3
kVA/kW from all receptacles. Generator power is not affected by weld
output.
EXAMPLE: If 15 A is drawn from
RC1, only 10 A is available at RC2:
(120 V x 15 A) + (120 V x 10 A) = 3.0
kVA/kW
Ref. 206 029
OM-480 Page 20
6-2. 240 Volt Duplex Receptacle (Optional)
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
1
1
240 V 15 A AC Receptacle
RC1
Receptacle supplies 60 Hz singlephase power at weld/power speed.
Maximum output is 3 kVA/kW.
2 Circuit Breakers CB1 And
CB2
CB1 and CB2 protect the
receptacles from overload. If CB1
or CB2 opens, the 240 V receptacle
and half of the 120 V receptacle
does not work. 120 volts may still be
present at the 240 V receptacle.
If a circuit breaker continues to
open, contact Factory Authorized Service Agent.
Combined output of all receptacles
is 3 kVA/kW. Generator power is
not affected by weld output.
EXAMPLE: If 10 A is drawn from the
240 V receptacle, only 5 A is available at the 120 V receptacle:
(240 V x 10 A) + (120 V x 5 A) = 3.0
kVA/kW
2
1
Ref. 206 029 / 174 408
OM-480 Page 21
6-3. Connecting Optional AC Power Plant
Stop engine.
Power and weld outputs are
live at the same time.
Disconnect
or
insulate
unused cables.
Have
qualified person install
according to circuit diagram
and Generator Power Guidelines (Section 10).
Remove junction box cover.
13
1
F3
2
12
Lead 93
2
Lead 92
3
Lead 91
4
Lead 90 (Neutral)
5
Lead 42 (Circuit Grounding
Lead)
Lead 42 connects to front panel
Ground stud.
15
14
1
6
Grounding Terminal
7
Jumper Lead 42
8
Isolated Neutral Terminal
Jumper 42 is connected to lead 90
at factory. Jumper 42 may be disconnected from neutral to meet
applicable electrical codes.
9
F2
3
Lead 80
10 Receptacle RC9 leads
11 Lead 42
F1
12 Lead 81
4
11
13 Lead 82
14 Load Terminals
Connect leads to terminals.
15 Fuses F1, F2, And F3
F1, F2, and F3 protect each load line
from overload.
10
5
9
93
91
90
92
8
7
6
AC
Output
Single
Phase
1
Three
Phase
3
Volts
120/240
240
Amps
31
24
KVA/KW
7.5
Frequency
Set
Engine Control switch to
Run when using generator
power.
10
60 Hz
Engine Speed
1850 RPM
Max. Fuse Size
35 Amperes
Lead 42 connects to GROUND stud on front of
unit.
Jumper 42 is connected to 90 at factory.
Tools Needed:
Ref. S-179 637-B
OM-480 Page 22
6-4. 120/240 Volt Twistlock Receptacle (Optional)
1
120/240 V 50 A Twistlock Receptacle RC9
RC9 is connected to the optional ac
power plant and supplies 60 Hz
single-phase power at weld/power
speed. Maximum output from receptacle is 7.5 kVA/kW.
Power available at RC9 is reduced
when welding.
1
Fuses F1 and F2 protect RC9 from
overload (see Section 6-3). If a fuse
opens, the receptacle does not
work. 120 volts may still be present
at RC9.
801 057-A
OM-480 Page 23
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING
7-1. Routine Maintenance
Stop engine before maintaining.
Recycle
engine
fluids.
See also Engine Manual and Maintenance Label.
Service engine more often if used in severe conditions.
*
To be done by Factory Authorized Service Agent.
8h
FUEL
WATER
Check Fluid
Levels. See
Section 4-4.
Wipe Up
Spills.
Drain Water
From Fuel
System. See
Section 7-4.
50 h
Clean And
Tighten Weld
Terminals.
Clean Air Filter.
See Section 7-3.
100 h
Check
air
cleaner hoses
for cracks and
loose clamps.
Clean And
Tighten
Battery
Connections.
Clean
Cooling
System.
200 h
250 h
Check And
Clean Spark
Arrestor. See
Section 7-8.
Replace
Unreadable
Labels.
500 h
Change Oil
Filter. See
Section 7-4.
Repair Or
Replace
Cracked
Cables.
Change Fuel
Filters. See
Section 7-4.
Service Welding
Generator Brushes
And Slip Rings.
Service More Often
In Dirty Conditions.*
Change Oil. See
Section 7-4.
1000 h
OR
1/2 in.
(13 mm)
Blow Out Or
Vacuum Inside.
During Heavy
Service,
Clean Monthly.
Check
Belt
Tension.
Drain Sludge
From Fuel
Tank. See
Section 7-4.
FUEL
SLUDGE
3000 h
Clean/Set
Injectors.*
OM-480 Page 24
Check
Valve
Clearance.*
NOTE
Follow the storage procedure in the engine owner’s manual if the unit will not be
used for an extended period.
7-2. Maintenance Label
OM-480 Page 25
7-3. Servicing Air Cleaner
Stop engine.
Do not run engine without air
cleaner or with dirty element. Engine 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 capacity of the filter is reduced with
each cleaning. The chance of dirt
reaching the clean side of the filter
while cleaning 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 element.
4
1
2
3
If you decide to clean the primary
element, we strongly recommend
installing an optional safety element
to provide additional engine protection. Never clean a safety element.
Replace the safety element after
servicing the primary element three
times.
8
7
1
6
9
5
Air Cleaner
2
Service Indicator (Optional)
3
Window
4
Reset Button
Service air cleaner element if red band
appears in window. A green band means
air cleaner is okay. Press button to reset
indicator.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
5
Housing
6
Safety Element (Optional)
7
Primary Element
8
Cover
9
Dust Ejector
To clean air filter:
Wipe off cover and housing. Remove
cover and dump out dust. Remove
element(s). Wipe dust from inside cover
and housing with damp cloth. Reinstall
safety element (if present). Reinstall
cover.
Keep nozzle
2 in (51 mm)
from element.
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Blow
Inspect
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 element if it has holes or damaged gaskets.
Reinstall primary element and cover
(dust ejector down).
aircleaner4 9/02– 802 495 / Ref. S-0698-B
OM-480 Page 26
7-4. Servicing Fuel And Lubrication Systems
Stop engine and let cool.
1
2
3
Oil Filter
Oil Drain Plug
Oil Fill Cap
4
Primary Fuel Filter (Fuel/
Water Separator)
5
Petcock
6
Secondary Fuel Filter
7
Fuel Shutoff Valve
8
Fuel Line
9
Sludge Drain Plug
To change oil and filter:
See engine manual.
To drain water from fuel system:
9
Open primary fuel filter petcock and
drain water into metal container.
Close petcock when water-free fuel
flows.
To replace primary fuel filter:
Close shutoff valve and turn filter
counterclockwise. Remove filter.
Apply thin coat of fuel to gasket on
new filter. Install new filter and turn
clockwise. Open shutoff valve.
Bleed air from fuel system according to engine manual.
Inspect fuel line, and replace if
cracked or worn.
To replace secondary fuel filter:
See engine manual.
To drain sludge from fuel tank:
3
Put metal container under drain,
and remove sludge drain plug. Reinstall plug when done.
After servicing, start engine
and check for fuel leaks.
Stop engine, tighten connections as necessary, and wipe
up spilled fuel.
Close doors.
1
6
2
7
4
Valve Open
8
5
Tools Needed:
7/16, 11/16 in
Ref. 800 159-E / Ref. 206 029
OM-480 Page 27
7-5. Adjusting Engine Speed
After tuning engine, check engine
no load speed with a tachometer
(see table for no load speeds). If
necessary, adjust speed as follows:
Start engine and run until warm.
Turn Amperage/Voltage Control to
100.
Standard Models:
1850 rpm
(61.6 Hz)
1250 rpm
(41.5 Hz)
1
Engine Speed Adjustment
Screw
2
Locking Nut
Loosen nut. Turn screw until engine
runs at 1850 rpm. Tighten nut.
Models With Automatic Idle
(Optional)
3
Throttle Rod
4
Locknut
Loosen locknuts. Place engine
control switch in Run/Idle position.
Turn throttle rod until engine runs at
idle speed. Tighten locknuts.
5
Engine Speed Adjustment
Screw
6
Locknut
Place engine control switch in Run
position.
Loosen locknut. Turn screw until
engine runs at weld/power speed.
Tighten locknut.
Standard Models
Stop engine.
2
1
Models With Automatic Idle (Optional)
4
3
4
5
6
Tools Needed:
3/8, 7/16 in
OM-480 Page 28
Ref. 801 179 / Ref. 800 159-D / Ref. 800 161
7-6. Overload Protection
Stop engine.
When a fuse opens, it usually
indicates a more serious problem exists. Contact a Factory
Authorized Service Agent.
1
Magnetic Shutdown Switch
MS1 (Optional)
2
Fuse F (See Parts List)
Fuse F protects magnetic shutdown switch MS1. If fuse F opens,
the engine stops.
3
Throttle Solenoid Fuse F4
(Optional)
Fuse F4 protects the throttle solenoid from overload on models with
automatic idle option. If fuse F4
opens, the engine does not run at
idle speed.
Check fuses and replace if open.
3
Tools Needed:
1
2
Ref. 156 199-B / 801 320-B
7-7. Servicing Optional Ether Starting Aid
Stop engine.
Improper handling or exposure to ether can harm your
health. Follow manufacturer’s safety instructions on
cylinder.
1
If engine does not start in cold
weather, check ether cylinder as
follows:
Remove cylinder from valve.
1
Ether Cylinder
2
Valve
3
Scale
Weigh cylinder to see if it is empty.
3
33 oz
(935 g)
Be sure atomizer is not plugged and
valve fitting is clean.
Replace cylinder according to
Section 4-5.
15 oz
(425 g)
Full
Empty
2
ether2 7/96 – 153 382-A / S-0692
OM-480 Page 29
7-8. Inspecting And Cleaning Optional Spark Arrestor
Stop engine and let cool.
1
Spark Arrestor
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.
3
2
1
Stop engine and let cool.
Reinstall cleanout plug.
Tools Needed:
3/8 in
800 523 / Ref. 206 029
7-9. Troubleshooting
A. Welding
Trouble
No weld output.
Remedy
Check position of Ampere Range switch.
Check position of optional Polarity switch.
Place A/V control switch in Panel position, or place switch in Remote position and connect Remote Amperage control to Remote A/V receptacle RC3 (see Section 5-3).
Check and secure connections to Remote A/V receptacle RC3.
Disconnect equipment from generator power receptacles during start-up.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output.
Use dry, properly stored electrode.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Check and tighten connections both inside and outside unit.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Low or high weld output.
Check control settings.
Check engine speed, and adjust if necessary (see Section 7-5).
Low open-circuit voltage.
Check engine speed, and adjust if necessary (see Section 7-5).
Have Factory Authorized Service Agent check integrated rectifier SR2, Amperage/Voltage control R1,
and resistor R2.
Maximum weld output only in each am- Have Factory Authorized Service Agent check Amperage/Voltage control R1, capacitor C8, diode D8,
pere range.
integrated rectifier SR4, and control relay CR2.
OM-480 Page 30
B. Generator Power
Trouble
No output
receptacles.
at
generator
Remedy
power Reset circuit breaker CB1 and/or CB2 (see Section 6-1 or 6-2).
Disconnect equipment from generator power receptacles during start-up.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Low or high output at generator power Check engine speed, and adjust if necessary (see Section 7-5).
receptacles.
Low output at optional ac power plant Check engine speed, and adjust if necessary (see Section 7-5).
junction box, or receptacle RC9.
If optional remote device is being used, set A/V Control switch in Remote position and remote device at
maximum (see Section 5-3).
If optional remote device not being used, set A/V Control switch in Panel position (see Section 5-3).
Check and replace fuses F1, F2, and/or F3, if necessary (see Section 6-3).
Have Factory Authorized Service Agent check brushes and slip rings.
No output from optional ac power plant; Check connections to ac power plant (see Section 6-3).
weld output and standard generator
power receptacle output okay.
Check fuses F1, F2, and F3 and replace if necessary (see Section 6-3).
C. Engine
Trouble
Engine does not start.
Remedy
Check fuel level. Open fuel valve (see Section 4-4).
Check optional Magnetic Shutdown switch fuse F and replace if open (see Section 7-6).
Check battery and replace if necessary.
Check connections to Engine Control switch.
Check oil level. Optional automatic shutdown system stops engine if oil pressure gets too low or oil
temperature gets too high.
See engine manual.
Have Factory Authorized Service Agent check engine charging system.
Engine suddenly stops.
Check oil level. Optional automatic shutdown system stops engine if oil pressure gets too low or oil
temperature gets too high.
Check optional Magnetic Shutdown switch fuse F and replace if open (see Section 7-6).
Engine slowly stopped; unable to restart Check fuel level. Open fuel valve (see Section 4-4).
engine.
Engine does not stop when Engine Con- Use manual shutoff lever to stop engine (see Section 5-1). Check connections to Engine Control switch.
trol switch is placed in Off position.
Have Factory Authorized Service Agent check engine fuel solenoid.
Engine remains at idle speed when Have Factory Authorized Service Agent check Engine Control switch and idle module.
Engine Control switch is placed in Run/
Idle position and an arc is struck (models
with automatic idle option only.)
Engine will not run at idle speed. (models Check throttle solenoid fuse F4, and replace if open (see Section 7-6).
with automatic idle option only.)
Have Factory Authorized Service Agent check Engine Control switch and idle module.
Battery discharges between uses.
Make sure Engine Control switch is in Off position when unit is shut down.
Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every three months).
Replace battery.
Engine uses oil during run-in period; Dry engine (see Section 9).
wetstacking occurs.
See engine manual.
OM-480 Page 31
SECTION 8 – ELECTRICAL DIAGRAM
SC-190 650-B
Figure 8-1. Circuit Diagram For Welding Generator
OM-480 Page 32
SECTION 9 – RUN-IN PROCEDURE
run_in1 8/01
9-1. Wetstacking
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
1
2
Welding Generator
Run diesel engines near rated voltage and current during run-in period
to properly seat piston rings and
prevent wetstacking. See nameplate, rating label, or specifications
section in this manual to find rated
voltage and current.
1
2
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.
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 additional engine run-in information.
OM-480 Page 33
9-2. Run-In Procedure Using Load Bank
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Keep exhaust and pipe away
from flammables.
4
2
1
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or generator auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maximum position, A/V control in minimum 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.
3
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 during 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.
S-0683
OM-480 Page 34
9-3. Run-In Procedure Using Resistance Grid
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Keep exhaust and pipe away
from flammables.
6
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
2
1 Resistance Grid
Use grid sized for generator rated
output.
1
Turn Off grid.
2 Welding Generator
Place A/V range switch in maximum position, A/V control in minimum 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 connectors (polarity is not important).
4
Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
3
5
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, rating label, or the specifications section in this manual).
4
+
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
Check oil level frequently during 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.
S-0684
OM-480 Page 35
SECTION 10 – GENERATOR POWER GUIDELINES
10-1. Selecting Equipment
1
2
3
Generator Power Receptacles
– Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
Do not use 2-prong plug unless equipment is double insulated.
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 6/02 – Ref. ST-159 730 / ST-800 577
0-2. Grounding Generator To Truck Or Trailer Frame
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
1
2
3
1
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
2
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
GND/PE
3
Electrically bond generator
frame to vehicle frame by
metal-to-metal contact.
S-0854
OM-480 Page 36
10-3. Grounding When Supplying Building Systems
1
1
2
Equipment Grounding
Terminal
Grounding Cable
2
GND/PE
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.
Use ground device as stated
in electrical codes.
2
3
ST-800 576-B
10-4. How Much Power Does Equipment Require?
1
3
2
1
VOLTS 115
AMPS 4.5
Hz
60
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-resistive load and requires approximately six times more power while
starting the motor than when running
(see Section 10-8).
3
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
AMPERES x VOLTS = WATTS
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.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-480 Page 37
10-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
10-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
OM-480 Page 38
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
10-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-480 Page 39
10-8. Power Required To Start Motor
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
1
2
3
4
2
Motor Start Code
Running Amperage
Motor HP
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 amperage (see example).
Welding generator amperage output must be at least twice the
motor’s running amperage.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230
HP = 1/4
Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A Starting the motor requires 12.2 amperes.
230
S-0624
10-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
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.
Ref. ST-800 396-A / S-0625
OM-480 Page 40
10-10. Typical Connections To Supply Standby Power
Properly install and ground this equipment according to
its Owner’s Manual and national, state, and local codes.
1
2
Utility
Electrical
Service
3
Transfer Switch
4
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
5
Essential
Loads
Have only qualified persons perform
these connections according to all
applicable codes and safety practices.
Switch transfers the electrical load from
electric utility service to the generator. Transfer load back to electric utility when service is
restored.
Properly install and ground this
equipment according to its Owner’s
Manual and national, state, and local
codes.
Install correct switch (customer-supplied).
Switch rating must be same as or greater
than the branch overcurrent protection.
Customer-supplied
equipment is required if generator will supply standby
power during emergencies or power outages.
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
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 voltage and wiring.
Connect generator with temporary or permanent 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 Section 10-4).
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-480 Page 41
10-11. 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)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (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)
5
1200
7
1680
10
2400
15
4
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
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-480 Page 42
6
Notes
OM-480 Page 43
SECTION 11 – PARTS LIST
Hardware is common and
not available unless listed.
3
2
4
5
1
16
7
8
15
18
14
9
125
17
13
124
12
123
11
122
10
119
71(Includes 72–77)
74
73
72
75
76
77
121
120
81
117
79
118
78
80
82
116
115 114
106
112
86
87
113
111(Fig 11-2)
83
88
89
84
85
110
109
108
107
106
105
91
99
98
102
101
100
103
97
92
96
93
95
94
104
Figure 11-1. Main Assembly
OM-480 Page 44
90
23
22
21
20
19
27
25
26
24
28
29
70
30
45
69
126
46
31
43
44
47
42
41
68
40
48
38
37
36
49
35
67
32
34
33
53
52
54
55
51
50
58
59
60
56
64
57
66
65(Fig 11–3)
61
62
63
ST-129 956-T
OM-480 Page 45
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . 134 771
. . . 2 . . . . . . . . . . . . . . . 184 676
. . . 3 . . . . . . . . . . . . . . . 182 022
. . . . . . . . . . . . . . . . . . . . . 605 288
. . . 4 . . . . . . . . . . . . . . . 020 185
. . . 5 . . . . . . . . . . . . . . . 073 432
. . . 6 . . . . . . . . . . . . . . . Deleted
. . . 7 . . . . . . . . . . . . . . . 125 687
. . . 8 . . . . . . . . . . . . . . . 192 757
. . . 9 . . . . . . . . . . . . . . . 097 507
. . . 10 . . . . . . . . . . . . . . . 188 235
. . . 11 . . . . . . . . . . . . . . . 017 479
. . . 12 . . . . . . . . . . . . . . . 111 352
. . . 13 . . . . . . . . . . . . . . . 108 081
. . . 14 . . . . . . . . . . . . . . . 124 941
. . . 15 . . . . . . . . . . . . . . . 089 914
. . . 16 . . . . . . . . . . . . . . . 124 668
. . . 17 . . . . . . . . . . . . . . . 010 460
. . . 18 . . . . . . . . . . . . . . . 032 453
. . . . . . . . . . . . . . . . . . . . . 049 026
. . . 19 . . . . . . . . . . . . . . +124 766
. . . 20 . . . . . . . . . . . . . . . 134 792
. . . 21 . . . . . . . . . . . . . . . 107 990
. . . 22 . . . . . . . . . . . . . . . 035 968
. . . . . . . . . . . . . . . . . . . . . 195 869
. . . 23 . . . . . . . . . . . . . . . 108 487
. . . 24 . . . . . . . . . . . . . . . 004 130
. . . 25 . . . . . . . . . . . . . . . 173 847
. . . 26 . . . . . . . . . . . . . . +124 687
. . . . . . . . . . . . . . . . . . . . +124 685
. . . . . . . . . . . . . . . . . . . . . 168 385
. . . . . . . . . . . . . . . . . . . . . 089 343
. . . 27 . . . . . . . . . . . . . . . 178 763
. . . 28 . . . . . . . . . . . . . . +162 741
. . . 29 . . . . . . . . . . . . . . . 146 994
. . . 30 . . . . . . . . . . . . . . . 107 343
. . . 31 . . . . . . . . . . . . . . . 197 614
. . . 32 . . . . . . . . . . . . . . . 197 613
. . . 33 . . . . . . . . . . . . . . . 197 675
. . . 34 . . . . . . . . . . . . . . . 197 677
. . . 35 . . . . . . . . . . . . . . *197 676
. . . 36 . . . . . . . . . . . . . ♦197 679
. . . 37 . . . . . . . . . . . . . . . 197 829
. . . 38 . . . . . . . . . . . . . . . 197 678
. . . 39 . . . . . . . . . . . . . . . Deleted
. . . 40 . . . . . . . . . . . . . . . 010 863
. . . 41 . . . . . . . . . . . . . . . 124 985
. . . 42 . . . . . . . . . . . . . . . 010 862
. . . 43 . . . . . . . . . . . . . ♦010 089
. . . 44 . . . . . . . . . . . . . ♦046 545
. . . 45 . . . . . . . . . . . . . . . 158 610
. . . 46 . . . . . . . . . . . . . . . 087 336
. . . 47 . . . . . . . . . . . . . . . 173 908
. . . . . . . . . . . . . . . . . . . . . 010 736
. . . 48 . . . . . . . . . . . . . . . 173 910
. . . 49 . . . . . . . . . . . . . . . 173 943
. . . . . . . . . . PLG5 . . . . 124 346
OM-480 Page 46
. . PLUG, protective .640sq . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . TANK, fuel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CAP, fuel large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FITTING, pipe galv plug sqhd .250NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FITTING, pipe brs elbow st 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FITTING, brs barbed M 3/16tbg x 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................................................................
. . HOSE, nprn SAE .125 ID x .343 OD (order by ft) . . . . . . . . . . . . . . . . . . . 1ft
. . FITTING, hose brs splice 3/16 tbg x 3/16 tbg . . . . . . . . . . . . . . . . . . . . . . 1
. . STRIP, rbr adh back 1.125 x 1.000 x 20.500 . . . . . . . . . . . . . . . . . . . . . . . 2
. . UPRIGHT, base center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BATTERY, stor 12V 380crk 80rsv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . 2
. . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BOLT, L stl .312-18 x 10.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STUD, stl .312-18 x 10.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SCREW, M10-1.5 x 25mm hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . WASHER, flat rbr 3.625 ID x 5.875 OD x .062thk . . . . . . . . . . . . . . . . . . . 1
. . CABLE TIE, 0-17.500 weather resistant . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning falling equipment can cause serious injury . . . . . . . . . . 2
. . BRACKET, support door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . LABEL, diesel engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . 1
. . RIVET, nyl .250dia x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . GUARD, belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . 1
. . GROMMET, rbr neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . AIR CLEANER, intake (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . DUST EJECTOR, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . COVER ASSY, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . ELEMENT, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . ELEMENT, air cleaner safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . BODY, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................................................................
. . CLAMP, hose 2.062 - 3.000clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOSE, air cleaner to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CLAMP, 1.812 - 2.500clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FITTING, pipe brs coupling 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RESTRICTION INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning electric shock and moving parts . . . . . . . . . . . . . . . . . . . 2
. . LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TUBING, stl .625 OD x 12ga wall x .625 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . WEATHERSTRIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . ENGINE, Deutz dsl elec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOUSING, plug nyl 8 contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . . . . . . . . . . . . . . . . . . . 128 287
. . . 50 . . . . . . . . . . . . . ♦127 648
. . . 51 . . . . . . . . . . . . . ♦127 994
. . . 52 . . . . . . . . . . . . . ♦175 936
. . . 53 . . . . . . . . . . . . . ♦126 388
. . . 54 . . . . . . . . . . . . . ♦194 036
. . . . . . . . . . . . . . . . . . . ♦010 021
. . . . . . . . . . . . . . . . . . . ♦072 082
. . . . . . . . . . . . . . . . . . . ♦118 679
. . . 55 . . . . . . . . . . . . . ♦125 663
. . . 56 . . . . . TS1 . . . ♦124 974
. . . 57 . . . . . . . . . . . . . ♦175 937
. . . 58 . . . . . . . . . . . . . . . 188 246
. . . 59 . . . . . . . . . . . . . . . 601 945
. . . 60 . . . . . . . . . . . . . . . 071 731
. . . 61 . . . . . . . . . . . . . . . 071 890
. . . 62 . . . . . . . . . . . . . . . 071 730
. . . 63 . . . . . . . . . . . . . . . 072 848
. . . 64 . . . . . . . . . . . . . . . 173 929
. . . 65 . . . . . . . . . . . . . . . Fig 11-3
. . . 66 . . . . . . . . . . . . . ♦030 084
. . . 67 . . . . . . . . . . . . . . . 188 239
. . . 68 . . . . . . . . . . . . . . . 109 591
. . . 69 . . . . . . . . . . . . . . . 124 866
. . . 70 . . . . . . . . . . . . . . . 087 341
. . . 71 . . . . . . . . . . . . . . . 200 788
. . . . . . . . . . . . . . . . . . . . . 208 858
. . . 72 . . . . . . . . . . . . . . . 110 069
. . . . . . . . . . . . . . . . . . . . . 106 394
. . . 73 . . . . . . . . . . . . . . . 080 389
. . . 74 . . . . . . . . . . . . . . . 124 607
. . . 75 . . . . . . . . . . . . . . . 172 684
. . . 76 . . . . . . . . . . . . . . . 200 787
. . . 77 . . . . . . . . . . . . . . . 145 282
. . . 78 . . . . . . . . . . . . . . . 134 835
. . . 79 . . . . . . . . . . . . . . . 010 323
. . . 80 . . . . . . . . . . . . . . . 192 744
. . . 81 . . . . . . . . . . . . . . . 145 283
. . . 82 . . . . . . . . . . . . . . . 188 250
. . . 83 . . . . . . . . . . . . . . . 010 146
. . . 84 . . . . . . . . . . . . . . . 123 794
. . . 85 . . . . . TE1 . . . . . 038 621
. . . . . . . . . . . . . . . . . . . . . 038 620
. . . . . . . . . . PLG7 . . ♦135 556
. . . 86 . CR98, CR99 ♦090 104
. . . 87 . . . Idle mod . ♦189 742
. . . 88 . . . . . . . . . . . . . ♦176 775
. . . 89 . . . . . . F4 . . . ♦073 429
. . . 90 . . . . . . . . . . . . . ♦046 432
. . . 91 . . . . . . . . . . . . . . . 053 967
. . . 92 . . . . . . . . . . . . . . . 081 499
. . . 93 . . . . . . . . . . . . . . . 179 637
. . . 94 . . . . . . . . . . . . . . . 113 730
. . . 95 . . . . . . . . . . . . +♦173 410
. . . 96 . . . . . . . . . . . . . ♦026 947
. . . 97 . . . . . . . . . . . . . ♦134 903
. . . 98 . . . . . . . . . . . . . ♦149 541
. . . 99 . . . . . . . . . . . . . *♦089 585
. . 100 . . SR1,2,4 . . . 035 704
. . STUD, adjusting throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLEVIS, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BALL JOINT, .250-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROD, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, .250-28 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, arm throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, stl cush .562dia x .343mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, stl .265 ID x .499 OD x .593 lg . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, M 6-1.0 x 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BALL JOINT, .250-28 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SOLENOID, 12VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, support solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg engine RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, cap stl hexhd .625-18 x 4.000 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER,flat stl .656 ID x 2.250 OD x .187thk . . . . . . . . . . . . . . . . . . . . .
. . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBING, stl .875 OD x 12ga wall x 2.375 . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBING, nprn .875 ID x 2.500 OD x 2.000 . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SHUNT, meter 50MV 600A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, muffler 1.750dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIPE, muffler extension elb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUMPER, door 1.000 OD x .750 high . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE, filter fuel (standard models – includes items 72 thru 77) . . . . . . .
. . BASE, filter fuel (models w/ 7.5/10 KVA opt. – incl items 72 thru 77) . .
. . . . FITTING, flrd brs elbow M 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, flrd brs conn M HD 1/4 tbg x 1/4 NPT(7.5/10 KVA option) .
. . . . SCREW, .312-18 x 1.000 cap hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STRIP, mtg separator fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, .312-18 x .50 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BASE, filter w/adapter and vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, hose brs barbed elb M 5/16tbg x 1/4NPT . . . . . . . . . . . . . . .
. . HOSE, SAE .312 ID x .560 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, hose .250-.625clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FILTER, fuel spin-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, fuel 10.000 1/4 swivel both ends . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, nyl .625 clamp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . EDGE TRIM, (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 30A 4P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 12VDC SPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MODULE, pull to idle 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg comp panel auto idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FUSE, mintr gl slo-blo 15A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, fuse mintr .250 x 1.250 panel mtg . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATION, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning auxiliary power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, fuse box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, fuse crtg 60A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FUSE, crtg 35A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
2
1
1
1
1
4
4
4
4
4
1
1
1
1
1
1
4
1
1
1
1
2
1
2
1
1
2ft
2
1
1
1
1
1ft
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
3
3
OM-480 Page 47
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . 101 . . . . . . . . . . . . . . 173 982
. . 102 . . . . RC9 . . . . 168 071
. . 103 . . . . . . . . . . . . ♦173 423
. . . . . . . . . . . . . . . . . . . . . 123 794
. . 104 . . . . . . . . . . . . ♦173 408
. . 105 . . . . . D8 . . . . . 192 307
. . 106 D1/C1, D9/C9 189 701
. . 107 . . . . . C8 . . . . . 170 674
. . 108 . . . . . R6 . . . . . 030 844
. . . . . . . . . . . . . . . . . . . . . 605 741
. . 109 . . . . CR2 . . . . 044 588
. . 110 . . . . . . . . . . . . . +173 317
. . 110 . . . . . . . . . . . +♦175 368
. . 111 . . . . . . . . . . . . . . Fig 11-2
. . 112 . . . . CT1 . . . ♦105 370
. . 113 . . . . . Z1 . . . . . 204 797
. . 114 . . . . Neg . . . . . 039 046
. . 115 . . . . Pos . . . . . 039 047
. . 116 . . . . . . . . . . . . ♦174 008
. . 117 . . . . R2,3 . . . . 189 699
. . 118 . . . . . . . . . . . . ♦174 010
. . . . . . . . . . . . . . . . . . . ♦059 773
. . 119 . . . . . . . . . . . . . . 085 656
. . 120 . . . . . . . . . . . . . . 188 237
. . 121 . . . . . . . . . . . . . . 108 163
. . 122 . . . . . . . . . . . . . . 110 069
. . 123 . . . . . . . . . . . . . . 010 314
. . 124 . . . . . . . . . . . . . . 070 010
. . 125 . . . . . . . . . . . . . . 089 517
. . 126 . . . . . . . . . . . . ♦175 465
. . . . . . . . . . . . . . . . . . . . . 173 919
. . . . . . . . . . . . . . . . . . . . . 168 071
. . . . . . . . . . . . . . . . . . . . . 165 669
. . . . . . . . . . . . . . . . . . . . . 116 045
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, 3P 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDGE TRIM, (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, diode w/washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, WW fxd 25W 25 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLIP, mtg resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 12VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg switch and output terminals . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, WW tap 375W 10 ohm w/mounting bracket . . . . . . . . . . . .
SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STRIP, mtg resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UPRIGHT, base front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRAME, mtg reactor & fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, brs flrd elbow M 1/4tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . .
VALVE, shut-off fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOLT, J stl .250-20 x 2.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STRAP, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, pipe brs adapter extender 1/8 x 1/8 120 . . . . . . . . . . . . . . . . . .
KIT, label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1ft
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
4
2
1
1
2
1
1
♦OPTIONAL
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*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.
Item
Dia.
Part
No.
Mkgs.
No.
Quantity
Description
Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 111)
. . . 1 . . . . S3 . . . . . . . 114 193 . . SWITCH, range (Fig 11-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . R1 . . . . . . . 605 960 . . RHEOSTAT, WW 300W 34 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . MS1 . . . . ♦011 072 . . . . SWITCH, magnetic (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . F . . . . . . *048 317 . . . . . FUSE, mintr gl 14A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . . 032 897 . . RECEPTACLE, twlk grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . CB1,2 . . . . . 139 266 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . .
. . . 7 . . . RC1,2 . . . . . 170 901 . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . GFCI1, 2 . . ♦151 981 . . RECEPTACLE, str dx grd 2P3W 15/20A GFCI . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd 2P3W 15A 125V Arrow Hart 5965V
. . . 8 . . . . . . . . . . . . . . . 601 836 . . NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . . . 083 030 . . STUD, brs grd .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and serial number) . . . . . .
. . . 11 . . . . . . . . . . . . . ♦046 652 . . METER, amp DC 50MV 0-600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . ♦046 654 . . METER, volt DC 0-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-480 Page 48
1
1
1
1
1
1
2
2
2
3
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 111) (Cont’d)
. . . 13 . . . . . . . . . . . . . . . 021 385 . .
. . . 14 . . . . . . . . . . . . . ♦129 860 . .
. . . . . . . . . . . . . . . . . . . ♦128 829 . .
. . . . . . . . . . . . . . . . . . . ♦128 633 . .
. . . 15 . . . . . . . . . . . . . ♦129 837 . .
. . . 16 . . . . . . . . . . . . . . . 119 014 . .
. . . 17 . . . . . . . . . . . . . . . 082 789 . .
. . . 18 . . . PL1,2 . . . . *048 155 . .
. . . 19 . . . . . . . . . . . . . . . 082 788 . .
. . . 20 . . . . HM . . . . . . 145 247 . .
. . . 21 . . . . . . . . . . . . . . . 019 602 . .
. . . 22 . . . . . . . . . . . . . . . 019 754 . .
. . . 23 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . S1 . . . . . . . 176 606 . .
. . . 25 . . . . . . . . . . . . . . . 127 618 . .
. . . 26 . . . . . . . . . . . . . . . 189 404 . .
BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GAUGE, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, oil line 44.000 in 1/8NPT x 10mm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, pipe brs adapter 1/8NPT x 12mm . . . . . . . . . . . . . . . . . . . . . . .
GAUGE, engine temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LENS, light ind red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BULB, incand flg base 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOLDER, light ind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METER, hour 4-40VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . .
SWITCH, ignition 4posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware is common and
1
2
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
Fig 11-4
not available unless listed.
25
24
2
3
4
23
26
5
6
7
22
21
20
19
18
10
9
17
16
15
14
8
13
12
11
ST-130 264-G
Figure 11-2. Panel, Front w/Components
♦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-480 Page 49
Hardware is common and
8
Figure 11-3. Generator
OM-480 Page 50
1
2
4
5
3
6
4
29
28
27
25
26
7
10
9
24
23
12
22
20
13
21
14
15
12
17
18
16
19
not available unless listed.
ST-110 922-F
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Generator (Fig 11-1 Item 65)
. . . 1 . . . . . . . . . . . . 106 426
. . . 2 . . . . . . . . . . . . 106 440
. . . 3 . . . SR3 . . . . 106 427
. . . 4 . . . . . . . . . . . . 048 420
. . . . . . . . . . . . . . . . . . 106 641
. . . 5 . . . . . . . . . . . . 037 957
. . . 6 . . . . . . . . . . . . 106 425
. . . . . . . . . . . . . . . . . . 188 387
. . . 7 . . . . . . . . . . . . 173 066
. . . 8 . . . . . . . . . . . . 600 270
. . . 9 . . . . . . . . . . . . 152 044
. . 10 . . . . . . . . . . . . *151 299
. . 11 . . . . . . . . . . . . . Deleted
. . 12 . . . . . . . . . . . . 013 367
. . 13 . . . . . . . . . . . . 124 855
. . 14 . . . . . . . . . . . +204 693
. . 14 . . . . . . . . . . +♦204 742
. . 15 . . . . . . . . . . . . 039 207
. . 16 . . . . . . . . . . . . 204 682
. . 17 . . . . . . . . . . . . 024 617
. . 18 . . . . . . . . . . . . 053 390
. . 19 . . . . . . . . . . . . 089 737
. . . . . . . . . . . . . . . . . . 035 776
. . 20 . . . . . . . . . . . . 204 695
. . 21 . . . . . . . . . . . . 204 714
. . 22 . . . . . . . . . . . . 173 068
. . 23 . . . . . . . . . . . . 143 220
. . 24 . . . . . . . . . . . . 173 323
. . 25 . . . SR3 . . . . 106 430
. . 26 . . . . . . . . . . . . 048 420
. . . . . . . . . . . . . . . . . . 106 641
. . 27 . . . . . . . . . . . . 106 425
. . 28 . . . . . . . . . . . . 037 956
. . 29 . VR1,R4 . . 046 819
. . INSULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . BUS BAR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . DIODE ASSEMBLY, reverse polarity (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . INSULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . BRUSHHOLDER/BRACKET ASSEMBLY, (consisting of) . . . . . . . . . . . . . . 3
. . . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CAP, brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.....................................................................
. . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . . 2
. . GUARD, starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STATOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STATOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . BAFFLE, air gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . ROTOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . RING, retaining external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . KEY, .375 x .375 x 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STATOR, exciter endbell (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . STATOR, exciter/aux power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . ENDBELL, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BARREL, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DIODE ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . INSULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-480 Page 51
Item
No.
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
1 .........
2 .........
3 .........
4 .........
5 .........
6 .........
7 .........
8 .........
9 .........
10 . . . . . . . .
11 . . . . . . . . .
12 . . . . . . . .
13 . . . . . . . .
Part
No.
Description
114 193
Figure 11-4. Switch, Range (Fig 11-2 Item 1)
114 235
010 671
017 428
004 998
011 980
011 645
011 076
011 953
011 074
011 644
004 999
011 012
100 623
Quantity
. . BRACKET, mtg switch (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SPRING, ext x .312 OD x .042 wire x 1.875pld . . . . . . . . . . . . . . . . . . . . . . .
. . LOCATOR, quadrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACT BOARD ASSEMBLY, switch range (consisting of) . . . . . . . . . . . .
. . . . CONTACT BOARD, movable switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONTACT ASSEMBLY, movable (consisting of) . . . . . . . . . . . . . . . . . . . . . .
. . . . . SPRING, pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . CONTACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . SPRING, pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONTACT, stationary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONTACT BOARD, stationary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SHIM, guide contact board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . GUIDE, contact board movable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
3
1
2
1
15
2
3
3
Hardware is common and
not available unless listed.
1
2
3
4
5
6
SB-011 273
Includes 8
Item 7
9
10
11
12
7
13
SB-011 100
Figure 11-4. Switch, Range
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-480 Page 52
Effective January 1, 2002
(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.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
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.
*
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
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
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, ZIPCUT & PLAZCUT 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.
miller_warr 6/02
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier to:
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.
PRINTED IN USA
 2002 Miller Electric Mfg. Co.
8/02