Miller Electric BIG BLUE 302P (PERKINS) Owner Manual

OM-496
197 761G
January 2001
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
Big Blue 302P And 452P
And Non-CE Models
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
Miller is the first welding help you figure out what the problem is. The
equipment manufacturer in parts list will then help you to decide which
the U.S.A. to be registered to
the ISO 9001 Quality System exact part you may need to fix the problem.
Standard.
Warranty and service information for your
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 or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
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
TIG = GTAW
MIG = GMAW
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
3
4
4
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
6
7
8
8
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions (CE Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturer’s Rating Labels For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
13
14
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Volt-Ampere Curves For CC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Volt-Ampere Curves For CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. AC Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Optional AC Power Plant Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
15
16
17
18
18
19
19
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator (See Sections 4-2 And 4-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Selecting Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models . . . . . . . . . . . . .
4-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models . . . . . . . . . . . . . . . . . . . . . .
20
20
20
21
21
22
23
24
25
25
26
27
SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls For CC Models (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Description Of Front Panel Controls For CC Models (See Section 5-1) . . . . . . . . . . . . . . . . .
5-3. Remote Amperage Control On CC Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
28
29
30
SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls For CC/CV Models (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1) . . . . . . . . . . . . . .
6-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) . . . . . . . . . . . . . . . . . . . . .
32
32
33
34
35
SECTION 7 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. 120 Volt And 240 Volt Duplex Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only) . . . . . . . . . . . . . . . . . .
7-3. Optional Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
36
37
38
(Continued)
TABLE OF CONTENTS
SECTION 8 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Adjusting Engine Speed On Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Adjusting Engine Speed On Models With Automatic Idle (Optional) . . . . . . . . . . . . . . . . . . . .
8-7. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Diagnosing Causes Of Engine Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
39
40
42
43
44
45
46
47
48
49
SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
SECTION 10 – RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
58
59
60
SECTION 11 – AUXILIARY POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
SECTION 12 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
OPTIONS AND ACCESSORIES
WARRANTY
Declaration of Conformity for
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit).
Miller Electric Mfg. Co.
Manufacturer’s Name:
Manufacturer’s Address:
Declares that the product:
1635 W. Spencer Street
Appleton, WI 54914 USA
Big Blue 452P
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Machinery Directives: 98/37/EEC,91/368/EEC, 93/C 133/04, 93/68/EEC
Noise level of Welding Generators: 84/535/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Standards
Safety Requirements for Arc Welding Equipment IEC 60974-1: 1998-09
Rotating Electrical Machines – Part 1: Rating and Performance: IEC 34-1: 1994
Rotating Electrical Machines – Part 5: Classification of degrees of protection provided by enclosure of rotating
electrical machines (IP code): IEC 34-5: 1991
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and test: IEC 60664-1: 2000-04
Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995
European Contact:
Telephone:
Fax:
dec_con1 5/98
Mr. Danilo Fedolfi, Managing Director
MILLER Europe S.P.A.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98290203
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
rom _nd_11/98
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 1-5. 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 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 after stopping
engine on inverters.
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
ARC RAYS can burn eyes and skin.
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.
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.
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.
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 an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-496 Page 1
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.
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.
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.
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.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
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.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
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.
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.
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
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.
OM-496 Page 2
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.
Turn cap slightly and let pressure escape slowly before completely
removing cap.
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.
BATTERY ACID can BURN SKIN and
EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
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.
ENGINE HEAT can cause fire.
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.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and –) on batteries.
Disconnect negative (–) cable first and connect it last.
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.
1-4. 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.
FLYING SPARKS can cause injury.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
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.
READ INSTRUCTIONS.
Use only genuine MILLER replacement parts.
Perform engine maintenance and service
according to this manual and the engine
manual.
OM-496 Page 3
H.F. RADIATION can cause interference.
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.
ARC WELDING can cause interference.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
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.
1-5. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
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.
To reduce magnetic fields in the workplace, use the following
procedures:
2. Arrange cables to one side and away from the operator.
OM-496 Page 4
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 11/98
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-496 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-496 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-496 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-496 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. Warning Label Definitions (CE Models Only)
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
Become trained and read the
instructions before working on the
machine or welding.
1
1.1
+
1.2
1
1.1
1.2
1.3
1.3
2
2.1
2
2.1
2.2
2.3
2.2
2.3
3
3
3.1
3.2
3.1
3.3
3.2
3.3
4
5
4.1
+
6
6.1
+
+
4
+
4.1
6.3
6.2
5
=
6
6.1
7
7.1
7.2
6.2
6.3
7
7.1
7.2
Electric shock from welding
electrode or wiring can kill.
Wear dry insulating gloves. Do
not touch electrode with bare
hand. Do not wear wet or
damaged gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Do not work on unit if engine
is running. Stop engine first.
Breathing welding fumes can
be hazardous to your health.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Welding sparks can cause
explosion or fire.
Keep flammables away from
welding. Do not weld near
flammables.
Welding sparks can cause
fires. Have a fire extinguisher
nearby,
and
have
a
watchperson ready to use it.
Do not weld on drums or any
closed containers.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding helmet
with correct shade of filter.
Wear
complete
body
protection.
Do not remove or paint over
(cover) the label.
Engine fuel plus flames or
sparks can cause fire.
Do not smoke while fueling or if
near fuel.
Stop engine before fueling.
Do not fuel a hot engine.
Engine exhaust gases can kill.
Vent exhaust outside.
Use unit outside.
S-176 105-A
3/96
OM-496 Page 9
2
1
3
4
5
1
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Do not smoke and keep
matches and flames away from
battery.
3 Sparks can cause battery
gases to explode. Battery
explosion can blind and injure.
Wear a face shield.
4 Battery acid can burn skin. Do
not spill acid.
5 Read Owner’s Manual.
6 Wear rubber gloves.
7 Dead battery
8 Engine block
9 Fully charged battery
10 Do not connect last negative
cable to dead battery – connect
instead to engine block.
11 Jumper cables – observe
polarity and make connections
in numbered sequence shown.
12 Once dead battery is charged,
disconnect cables in sequence
3/96
shown.
6
10
+ –
1
1
4
4
11
+
+
–
–
3
3
2
2
7
+
+
–
–
S-176 108
8
9
12
1
1
2
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
injury. Keep away from moving
parts.
3/96
S-176 106
Starting Aid Switch. Below 32°F (0°C),
push switch up for 60 seconds before
starting engine.
Starting Instructions:
1
2
3
4
OM-496 Page 10
Press and hold Magnetic
Shutdown switch.
Turn Engine Control switch to
Start position.
Release Engine Control switch
and Starting Aid switch (if used)
when engine starts.
Continue holding
Magnetic
Shutdown switch for 3 seconds
after engine starts.
1
1
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Hot muffler and exhaust pipes
can cause severe burns. Do
not touch hot muffler or pipes.
2
S-176 230
3/96
1
1
2
3
2
3
+
4
4
5
6
5
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Engine fuel plus flames or
sparks can cause fire.
Do not smoke while fueling or if
near fuel.
Stop engine before fueling.
Do not fuel a hot engine.
Use Diesel Fuel only.
6
DIESEL
S-176 103
3/96
1
1
2
3
4
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling equipment can cause
serious injury and damage.
Use lifting eye to lift or move
unit
only.
Use
proper
equipment when lifting.
Do not use lifting eye to lift and
support unit and trailer or other
heavy devices or accessories.
S-176 104
2
3
4
3/96
OM-496 Page 11
1
1
2
2
3
4
5
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Fire hazard from leaking
engine fuel. Fire can result from
welding
on
base
at
non-designated areas causing
a possible fuel leak.
Fuel tank is located inside
base.
Do not weld on base of unit.
Weld only on supplied brackets
or bolt unit down.
5
3
4
1
1
2
3
2
3
OM-496 Page 12
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
injury. Keep away from moving
parts.
S-177 571
1
+
2
1
2
3
+
3
4
DIESEL
5
4
6
5
7
0 – 50 h Std.
200A
Remove unit from shipping
crate. Remove Owner’s
Manual from unit. Follow
instructions to install muffler.
Read Owner’s Manual. Read
labels on unit.
Use Diesel Fuel only, and fill
fuel tank. Leave room for
expansion.
Warning! Watch Out! There
are possible hazards as
shown by the symbols. Read
Owner’s Manual. Follow
instructions to activate
battery.
Check oil level. Add oil if
necessary.
During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
After the first 50 hours of
operation, change the oil and
oil filter.
0 – 200A
50 h Std.
API CD-MIL L 2104D,
CD/SE, CD/SF
3/96
2-2. Manufacturer’s Rating Labels For CE Products
OM-496 Page 13
2-3. Symbols And Definitions
NOTE
Some symbols are found only on CE products.
Stop Engine
Fast (Run, Weld/
Power)
Slow (Idle)
Start Engine
Starting Aid
Battery (Engine)
Engine Oil
Pressure
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
Panel/Local
Remote
Engine
Air Temperature Or
Engine
Temperature
Output
Alternating
Current
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
TIG (GTAW)
Time
Hours
Seconds
A
3
Amperes
V
h
Three Phase
Electrode
Connection
s
Read Operator’s
Manual
Circuit Breaker
Work Connection
Engine-Driven,
Three-Phase
Alternator With
Rectifier
G
X
Duty Cycle
U0
Rated No Load
Voltage (Average)
U2
Conventional
Load Voltage
n1
Rated Idle
Speed
n0
Rated No Load
Speed
I
Current
Contactor On
OM-496 Page 14
1
Single Phase
Do Not Switch
While Welding
Hz
n
I2
Hertz
Rated Load
Speed
Rated Welding
Current
SECTION 3 – SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
CC/DC
Weld Output
Range
Maximum
OpenCircuit
Voltage
Rated Welding
Output
45 – 500 A
(CC Models)
20 – 500 A
(CC/CV Models)
Auxiliary Power Rating
Standard
Single-Phase,
4 kVA/kW, 34/17 A,
120/240 V AC,
50/60 Hz
95
300 A, 40 Volts DC,
100% Duty Cycle
400 A, 40 Volts DC,
60% Duty Cycle
CV/DC
(CC/CV
Models
Only)
14 – 40 V
500 A, 30 Volts DC,
40% Duty Cycle
Fuel
Capacity
Engine
Perkins
Perkins 104-22
Full kVA Option*
Water-Cooled,
Single-Phase/Three-Phase,
Four-Cylinder,
12/15 kVA/kW, 50/36A,
32.8 HP Diesel Engine
120/240 VAC, 60 Hz
56
25 gal
(95 L)
*In Addition To Standard
4 kVA/kW Auxiliary Power
3-2. Dimensions, Weights, And Operating Angles
Dimensions
Height
60 in (1524 mm)
(to top of muffler)
G
28-1/2 in (724 mm)
(mtg. brackets turned in)
Do not exceed tilt angles or engine could
be damaged or unit could tip.
30-3/4 in (781 mm)
(mtg. brackets turned out)
Do not move or operate unit where it could
tip.
Width
Depth
64-7/16 in (1637 mm)
A
64-7/16 in (1637 mm)
B
55-7/8 in (1419 mm)
C
46-3/8 in (1178)
D
9-1/2 in (241 mm)
E
27-1/2 in (699 mm)
A
B
F
1 in (25 mm)
G
29-1/2 in (743 mm)
H
9/16 in (14 mm) Dia.
4 Holes
Weight
w/ Perkins
104-22
No fuel: 1600 lb (726 kg)
w/fuel: 1775 lb (805 kg)
C
30°
H
20°
D
30°
20°
Front Panel End
F
E
802 161-A
OM-496 Page 15
3-3. Volt-Ampere Curves For CC Models
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
100
Ranges
280 – MAX
200 – 415
120 – 250
80 – 150
45 – 90
VOLTS
80
60
40
20
0
0
100
200
300
400
500
600
700
AMPERES
198 864
OM-496 Page 16
3-4. Volt-Ampere Curves For CC/CV Models
A. Stick Mode
100
Ranges
280 – Max
160 – 415
90 – 240
60 – 130
40 – 80
DC VOLTS
80
60
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
40
20
0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
B. MIG Mode
100
DC VOLTS
80
60
MAX
40
20
MIN
0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
C. TIG Mode
100
DC VOLTS
80
Ranges
60 – 320
40 – 160
30 – 110
20 – 70
60
40
20
0
0
50 100 150 200 250 300 350 400 450 500
DC AMPERES
198 865 / 198 866 / 198 867
OM-496 Page 17
3-5. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
2.00
1.75
US Gal./Hr.
1.50
1.25
1.00
0.75
0.50
0.25
IDLE
0.00
0
50
100
150
200
250
300
350
400
DC WELD AMPERES AT 100% DUTY CYCLE
199 032
3-6. Duty Cycle And Overheating
100% Duty Cycle At 300 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.
WELD AMPERES
Continuous Welding
% DUTY CYCLE
199 140
OM-496 Page 18
3-7. AC Auxiliary Power Curve
The ac power curve shows the auxiliary power in amperes available at
the 120 and 240 volt receptacles.
150 300
AC VOLTS
125 250
100 200
75 150
50 100
25
50
0
0
0
0
5
10
15
20
AC AMPERES IN 240V MODE
10
20
30
40
AC AMPERES IN 120V MODE
25
30
50
60
193 018
3-8. Optional AC Power Plant Curves
A. 12 kVA/kW Single-Phase Auxiliary Power Plant (No Weld Load)
280
The ac power curves show the auxiliary power available in amperes at
the single-phase 120/240 volt receptacle or three-phase 240 volt
terminals.
AC VOLTS
260
240
220
200
180
0
20
40
60
80
100
AC AMPERES
B. 15 kVA/kW Three-Phase Auxiliary Power Plant (No Weld Load)
280
AC VOLTS
260
240
220
200
180
0
10
20
30
40
AC AMPERES
50
60
70
198 868 /98 869
OM-496 Page 19
SECTION 4 – INSTALLATION
4-1. Installing Welding Generator (See Sections 4-2 And 4-3)
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
3
1
4
GND/PE
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
OR
1
2
3
2
Electrically bond generator frame to
vehicle frame by metal-to-metal
contact.
2
4
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
install1 10/00 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
4-2. Using Lifting Eye
1
2
3
1
Lifting Eye
Nut
Carriage Bolt
Raise lifting eye until it snaps in
place. Lower lifting eye when not
needed.
2
To lock the lifting eye in the upright
position, insert a 3/8-16 x 1-1/2 in
carriage bolt through slot in bracket
and secure with nut (bolt and nut not
supplied).
Tools Needed:
3
Ref. 802 169-E
OM-496 Page 20
4-3. Mounting Welding Generator
Do not weld on base. Welding on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
1
1
2
3
Mounting Bracket
1/2 in Bolt And Washer
(Minimum – Not Supplied)
3/8-16 x 1 in Screws
(Supplied)
To Bolt Unit In Place:
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
Welding Unit In Place
Bolting Unit In Place
2
1
Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
Tools Needed:
9/16 in
3
Ref. 190 250-A / Ref. 802 169-E
4-4. Installing Exhaust Pipe
Stop engine and let cool.
Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in
Ref. 802 169-E / Ref. 197 784
OM-496 Page 21
4-5. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1
5
4
1
2
3
4
5
Eye Protection – Safety
Glasses Or Face Shield
Rubber Gloves
Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
Well
Fill each cell with electrolyte to
bottom of well (maximum).
3
Do not overfill battery cells.
Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
6
Battery Charger
Read and follow all instructions supplied with battery
charger.
2
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 amperes. Disconnect charging cables
and install battery.
When electrolyte
is low, add
only distilled water to cells to
maintain proper level.
6
5 A For 30 Minutes
Tools Needed:
OR
+
–
rubber gloves
30 A For 12 Minutes
glasses
drybatt1 1/98 – 0886
OM-496 Page 22
4-6. Connecting The Battery
Connect Negative (–) Cable Last.
+
–
Tools Needed:
1/2 in
802 168-B / Ref. 197 784 / 802 313 / S-0756-C
Notes
OM-496 Page 23
4-7. Engine Prestart Checks
Check radiator coolant level when
fluid is low in recovery tank.
Full
Capacity: w/Overflow
Tank 12 qt (11.4L)
Full
Diesel
Full
Coolant Recovery Tank
Hot Full
Cold Full
802 490-D
Check all engine fluids daily.
Engine must be cold and on a level surface.
Unit is shipped with 20W break-in oil.
Automatic shutdown system stops engine if
fuel level or oil pressure is too low, or coolant
temperature is too high.
This unit has a low oil pressure shut-
down switch. However, some 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.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 10.
Fuel
Do not use gasoline. Gasoline will
damage engine.
The unit is shipped with enough fuel to prevent air from entering fuel system but not
enough fuel to prevent low fuel shutdown.
Add fresh diesel fuel before starting to preOM-496 Page 24
vent low fuel shutdown (see engine maintenance label for fuel specifications).
Do not run out of fuel or air will enter fuel system and cause 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).
Coolant
Check coolant level in radiator before starting unit the first time. If necessary, add coolant to radiator until coolant level is at bottom
of filler neck.
Check coolant level in recovery tank daily.
If necessary, add coolant to recovery tank
until coolant level is between Cold Full and
Hot Full levels. If recovery tank coolant level
was low, also check coolant level in radiator.
Add coolant if level is below bottom of radiator filler neck.
Engine coolant is a mixture of water and
ethylene glycol base antifreeze. Add anti-
freeze to mixture if using the unit in temperatures below –34° F (–37° C).
Keep radiator and air intake clean and free
of dirt.
Incorrect engine temperature can
damage engine. Do not run engine
without a properly working thermostat and radiator cap.
To improve cold weather starting:
Use Starting Aid switch (see Section
5-1 or 6-1).
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
(see Section 8-1).
4-8. Connecting To Weld Output Terminals
Stop engine.
1
Positive (+) Weld Output
Terminal
2
Negative (–) Weld Output Terminal
For Stick and TIG welding Direct
Current
Electrode
Positive
(DCEP), connect electrode holder
cable to Positive (+) terminal on left
and work cable to Negative (–) terminal on right.
For Direct Current Electrode Negative (DCEN), reverse cable
connections.
If equipped with optional polarity
switch, connect electrode holder
cable to Electrode terminal on left
and work cable to Work terminal on
right.
For MIG and FCAW welding Direct
Current Electrode Positive (DCEP)
on CC/CV models, connect wire
feeder cable to Positive (+) terminal
on left and work cable to Negative
(–) terminal on right. Use Process/
Contactor switch to select type of
weld output (see Section 6-3).
For Direct Current Electrode Negative (DCEN), reverse cable
connections.
1
2
Tools Needed:
If equipped with optional polarity
switch, connect wire feeder cable to
Electrode terminal on left and work
cable to Work terminal on right.
3/4 in
802 311-D
4-9. Selecting Weld Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
Welding
Amperes
100 ft (30 m) Or Less
150 ft
(45 m)
10 – 60%
Duty Cycle
60 – 100%
Duty Cycle
100
4
4
4
150
3
3
200
3
2
250
2
300
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
10 – 100% Duty Cycle
3
2
1
1/0
1/0
2
1
1/0
2/0
3/0
3/0
1
1/0
2/0
3/0
4/0
4/0
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
*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. Contact your
distributor for the mm2 equivalent weld cable sizes.
S-0007-E
OM-496 Page 25
4-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models
1
Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
RC13 (see Section 5-3).
1
Ref. 154 862-A / 048 720-K / 802 311-D
OM-496 Page 26
4-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
Socket*
Socket Information
A
24 volts ac. Protected by circuit
breaker CB6.
B
Contact closure to A completes
24 volt ac contactor control
circuit.
C
Output to remote control:+10
volts dc in MIG or Stick mode;
0 to +10 volts dc in TIG mode.
D
Remote control circuit common.
E
DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
24 VOLTS AC
REMOTE
OUTPUT
CONTROL
New! LDR-14 long
distance remote
(includes 120 V
receptacle)
OR
I
115 volts, 10 amperes, 60 Hz
ac. Protected by circuit breaker
CB6.
J
Contact closure to I completes
115 volt ac contactor control
circuit.
K
Chassis common.
G
Circuit common for 24 and 115
volt ac circuit.
115 VOLTS AC
GND
NEUTRAL
*The remaining sockets are not used.
OM-496 Page 27
SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS
5-1. Front Panel Controls For CC Models (See Section 5-2)
5
13
14
18
19
10 11
6
4
12
7
9
8
2
15
16
3
1
17
197 784 / 802 311-D
OM-496 Page 28
5-2. Description Of Front Panel Controls For CC Models (See Section 5-1)
Engine Starting Controls
1
Magnetic Shutdown Switch
Use switch during start-up to bypass engine
shutdown system. System stops engine if oil
pressure or fuel level is too low or coolant temperature is too high.
2
Starting Aid Switch
Use switch to energize starting aid for cold
weather starting (see starting instructions following).
3
Engine Control Switch
Use switch to start engine, select engine
speed ( if unit has auto idle option), and stop
engine.
6 Engine Oil Pressure Light
Light goes on and engine stops if oil pressure
is below 5 psi (34 kPa). Light goes on momentarily during start-up but goes out when engine reaches normal oil pressure.
Stop engine and fix trouble if Engine
Oil Pressure light stays on after startup.
7 Fuel Light
Light goes on and engine stops if fuel level is
low. Add fuel to resume operation.
13 Ampere Range Switch
8
14 Amperage Adjust Control
Engine Hour Meter
Engine Gauges
To
read gauges and engine indicator
lights with engine off, turn Engine Control
switch to Run/Idle and press Magnetic
Shutdown switch (see Section 8-9).
In Run position, engine runs at weld/power
speed. In Run/Idle position (optional), engine
runs at idle speed at no load and weld speed
with load applied.
9
To Start:
Use gauge to check fuel level.
If engine does not start, let engine come
to a complete stop before attempting restart.
Above 325 F (05 C): turn Engine Control
switch to Start while pressing Shutdown
switch. Release Engine Control switch when
engine starts. Continue holding Shutdown
switch until engine indicator lights go out.
Below 325 F (05 C): turn engine control switch
to Run/Idle position. Push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, press Magnetic Shutdown switch
and turn Engine Control switch to Start. Release Engine Control switch and Starting Aid
switch when engine starts. Continue holding
Shutdown switch until engine indicator lights
go out.
Fuel Gauge
To check fuel level when engine is not running, turn Engine Control switch to Run/Idle
position and press Magnetic Shutdown
switch.
10 Battery Voltmeter (Optional)
Use gauge to check battery voltage and monitor the engine charging system. The meter
should read about 14 volts dc when the engine is running, and about 12 volts dc when
the engine is stopped.
11 Engine Coolant Temperature Gauge
(Optional)
Normal temperature is 180 - 203° F (82 - 95°
C). When equipped with gauge option, engine
stops if temperature exceeds 220° F (104° C).
12 Engine Oil Pressure Gauge (Optional)
Engine Indicator Lights
Normal pressure is 30 – 60 psi (207 – 414
kPa). When equipped with gauge option, engine stops if pressure is below 10 psi (69
kPa).
4
Weld Controls
To Stop: turn Engine Control switch to Off
position.
Battery Charging Light
Light goes on if engine alternator is not charging battery. Engine continues to run.
Stop engine and fix trouble if Battery
Charging light goes on.
5
Engine Temperature Light
Light goes on and engine stops if engine temperature is above 221 ° F (105° C).
Stop engine and fix trouble if Engine
Temperature light goes on.
The max OCV circuit is disabled when
the Stick/TIG Selection switch is in
Scratch Start TIG position (see item 15).
Max OCV Control Circuit: This unit has
a max OCV control circuit that resets Amperage Adjust control R1 to maximum
when the arc breaks. When an arc is
struck, weld output control returns to the
R1 front panel or combination front panel/
remote control setting. The Amperage
Adjust control adjusts amperage only
when welding and does not adjust opencircuit voltage.
Do not switch under load.
Use switch to select weld amperage range.
For most welding applications, use lowest
amperage range possible to help prevent arc
outages.
Control adjusts amperage within range selected by Ampere Range switch. Weld output
would be about 185 A DC with controls set as
shown (50% of 120 to 250 A).
The numbers around the control are for
reference only and do not represent an
actual percentage value.
15 Stick/TIG Selection Switch
Use switch to disable max OCV circuit for
scratch start TIG welding (see max OCV note
under Weld Controls). When switch is in Stick
position, the max OCV circuit resets Amperage Adjust Control R1 to maximum when the
arc breaks. When switch is in Scratch Start
TIG position, max OCV circuit is disabled and
OCV changes when the control is adjusted.
16 Amperage Adjust Switch And Remote
Amperage Adjust Receptacle
Connect optional remote control to RC13
(See Section 4-10). Use switch to select front
panel or remote amperage control. For remote control, place switch in Remote position
and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 4-10 and 5-3).
17 Polarity Switch (Optional)
Do not switch under load.
Use switch to change weld output. Select either DC Electrode Positive (DCEP) or DC
Electrode Negative (DCEN).
Weld Meters
18 DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
19 DC Ammeter (Optional)
Ammeter displays amperage output of the
unit.
OM-496 Page 29
5-3. Remote Amperage Control On CC Models (Optional)
1
Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
RC13 (see Section 4-10).
1
In Example:
Range = 120 to 250 A DC
Percentage Of Range = 50%
Max = About 185 A DC (50% of 120 to 250)
Example: Combination Remote Amperage Control (Stick)
Max (185 A DC)
Min (89 A DC)
Set Switches
Set Range
Set Control
Adjust Optional Remote Control
0774 / Ref. 154 862-A / Ref. 181 711-A / 802 160-D
OM-496 Page 30
Notes
OM-496 Page 31
SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS
6-1. Front Panel Controls For CC/CV Models (See Section 6-2)
5
14
15
18
19
10 11
6
4
12
7
9
8
2
13
16
3
1
17
197 785 / 802 311-D
OM-496 Page 32
6-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1)
Engine Starting Controls
1
Magnetic Shutdown Switch
Use switch during start-up to bypass engine
shutdown system. System stops engine if oil
pressure is too low or engine temperature is
too high.
2
Starting Aid Switch
Use switch to energize starting aid for cold
weather starting (see starting instructions following).
3
Engine Control Switch
Use switch to start engine, select engine
speed ( if unit has auto idle option), and stop
engine.
In Run position, engine runs at weld/power
speed. In Run/Idle position (optional), engine
runs at idle speed at no load and weld speed
with load applied. Turn to run position if using
optional auxiliary power plant (see Section
7-2).
Light goes on and engine stops if engine temperature is above 221 ° F (105° C).
Stop engine and fix trouble if Engine
Temperature light goes on.
6
Light goes on and engine stops if oil pressure
is below 5 psi (34 kPa). Light goes on momentarily during start-up but goes out when engine reaches normal oil pressure.
Stop engine and fix trouble if Engine
Oil Pressure light stays on after startup.
7
to a complete stop before attempting restart.
Above 325 F (05 C): turn Engine Control
switch to Start while pressing Shutdown
switch. Release Engine Control switch when
engine starts. Continue holding Shutdown
switch until engine indicator lights go out.
Below 325 F (05 C): turn engine control switch
to Run/Idle position. Push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, press Magnetic Shutdown switch
and turn Engine Control switch to Start. Release Engine Control switch and Starting Aid
switch when engine starts. Continue holding
Shutdown switch until engine indicator lights
go out.
Fuel Light
Light goes on and engine stops if fuel level is
low. Add fuel to resume operation.
8
Engine Hour Meter
Engine Gauges
To
read gauges and engine indicator
lights with engine off, turn Engine Control
switch to Run/Idle and press Magnetic
Shutdown switch (see Section 8-9).
To Start:
If engine does not start, let engine come
Engine Oil Pressure Light
9
Fuel Gauge
Use gauge to check fuel level.
To check fuel level when engine is not running, turn Engine Control switch to Run/Idle
position and press Magnetic Shutdown
switch.
10 Battery Voltmeter (Optional)
Use gauge to check battery voltage and monitor the engine charging system. The meter
should read about 14 volts dc when the engine is running, and about 12 volts dc when
the engine is stopped.
11 Engine Coolant Temperature Gauge
(Optional)
See Section 6-3 for Process/Contactor
switch information.
14 Ampere Range Switch
Do not switch under load.
Use switch to select weld amperage range.
Use any range for Stick welding. Read the upper set of numbers at each range.
Use the lower four ranges for TIG welding.
Read the lower set of numbers at each range.
Use the highest range for MIG welding and for
cutting and gouging (CAC-A).
For most welding applications, use lowest
amperage range possible to help prevent arc
outages.
15 Voltage/Amperage Adjust Control
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage
within range selected by Ampere Range
switch. With Process/Contactor switch in any
MIG position, use control to adjust voltage.
With Voltage/Amperage Adjust Switch in Remote position, control limits the remote amperage in TIG mode, but has no effect in Stick
and MIG modes.
The numbers around the control are for
reference only and do not represent an
actual percentage value.
16 Voltage/Amperage Adjust Switch And
Remote 14 Receptacle
Use switch to select front panel or remote
voltage/amperage control. For remote control, place switch in Remote position and connect remote control to Remote 14 receptacle
RC14 (see Sections 4-11 and 6-4).
17 Polarity Switch (Optional)
Do not switch under load.
Use switch to change weld output. Select either DC Electrode Positive (DCEP) or DC
Electrode Negative (DCEN).
Weld Meters
18 DC Voltmeter (Optional)
To Stop: turn Engine Control switch to Off
position.
Normal temperature is 180 - 203° F (82 - 95°
C). When equipped with gauge option, engine
stops if temperature exceeds 220° F (104° C).
Engine Indicator Lights
12 Engine Oil Pressure Gauge (Optional)
4
Normal pressure is 30 – 60 psi (207 – 414
kPa). When equipped with gauge option, engine stops if pressure is below 10 psi (69
kPa).
Voltmeter displays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
19 DC Ammeter (Optional)
Weld Controls
Ammeter displays amperage output of the
unit.
Battery Charging Light
Light goes on if engine alternator is not charging battery. Engine continues to run.
Stop engine and fix trouble if Battery
Charging light goes on.
5 Engine Temperature Light
13 Process/Contactor Switch
OM-496 Page 33
6-3. Process/Contactor Switch On CC/CV Models
1
1
Process/Contactor Switch
Weld output terminals are energized when Process/Contactor switch is in an Electrode
Hot position and the engine is
running.
Use switch to select weld process
and weld output on/off control (see
table below and Section 6-4).
Place switch in Remote positions to
turn weld output on and off with a device connected to the remote 14 receptacle.
Place switch in Electrode Hot positions for weld output to be on whenever the engine is running.
Use Stick position for air carbon arc
(CAC-A) cutting and gouging.
Place switch in Electrode Hot -
Stick position when using optional auxiliary power plant (see Section 7-2).
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Remote – TIG
GTAW With HF Unit, Pulsing Device,
Or Remote Control
At Remote 14 Receptacle
Remote – Stick
Stick (SMAW) With Remote On/Off
At Remote 14 Receptacle
Remote – MIG
MIG (GMAW)
At Remote 14 Receptacle
Electrode Hot – MIG
MIG (GMAW)
Electrode Hot
Electrode Hot – Stick
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting And Gouging
Electrode Hot
Electrode Hot – Scratch
Start TIG
Scratch Start TIG (GTAW)
Electrode Hot
OM-496 Page 34
6-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)
1
Remote 14 Receptacle RC14
Connect optional remote control to
RC14 (see Section 4-11).
1
In Example:
Process = Stick (Using Remote On/Off)
Range = 90 to 240 A DC
Min = 90 A DC
Max = 240 A DC
Example: Combination Remote Amperage Control (Stick)
Max (240 A DC)
Min (90 A DC)
Set V/A
Adjust Switch
Set Remote
Process
Set Range
Control Not
Used In Remote
Stick Mode
Adjust Optional Remote Control
In Example:
Process = TIG (Using Remote On/Off)
Range = 40 to 160 A DC
Percentage Of Range = 50%
Min = 40 A DC
Max = About 100 A DC (50% of 40 to 160)
Example: Combination Remote Amperage Control (TIG)
Max (100 A DC)
Min (40 A DC)
Set V/A
Adjust Switch
Set Remote
Process
Set Range
Set Control
Adjust Optional Remote Control
0774 / Ref. 197 785 / 802 169-E
OM-496 Page 35
SECTION 7 – OPERATING AUXILIARY EQUIPMENT
7-1. 120 Volt And 240 Volt Duplex Receptacles
1
120 V 20 A AC GFCI
Receptacle GFCI1
2
240 V 20 A AC Twistlock
Receptacle RC1
Receptacles supply 60 Hz singlephase power at weld/power speed.
1
3
2
If a ground fault is detected, GFCI
Reset button pops out and
receptacle does not work. Check
for faulty tools plugged in
receptacle. Press button to reset
GFCI1.
At least once a month, run en-
gine at weld/power speed and
press test button to verify GFCI
is working properly.
4
3
Circuit Breaker CB1
4
Circuit Breaker CB2
CB1 protects RC1 and GFCI1 from
overload. If CB1 opens, RC1 and
GFCI1 do not work. Place switch in
On position to reset breaker.
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset breaker.
If a circuit breaker continues to
open, contact Factory Authorized Service Agent.
Auxiliary power is not affected
by weld output.
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all receptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
191 624-A
OM-496 Page 36
7-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only)
Place Process/Contactor switch
1
Single-Phase Power Connection
in Electrode Hot - Stick position
when using auxiliary power plant
(see Section 6-3).
2
Place Engine Control switch in
Run position when using auxiliary power plant.
Single-Phase Auxiliary Power
1
120/240 V 50 A Receptacle
RC5
RC5 is connected to the optional
auxiliary power plant and supplies 60
Hz single-phase power at weld/power speed. Maximum output from RC5
is 12 kVA/kW. Power available at
RC5 is reduced when welding.
2
Three-Phase Power Connection
Circuit breaker CB7 protects singlephase receptacle RC5 and the load
wires from overload. If CB7 opens, all
auxiliary power plant output stops
and the receptacle does not work.
Volts
Single
Phase
1
120/240
Three
Phase
3
240
Amps
50
36
Stop engine.
KVA/KW
12
15
Power and weld outputs are
live at the same time. Disconnect or insulate unused
cables.
AC
Output
Close panel opening
if no connections are
made to power plant.
Frequency
Engine Speed
60 Hz
1850 RPM
Lead 42 connects to GROUND stud on
front of unit.
Jumper 42 is connected to 90 at factory.
Three-Phase Auxiliary Power
Have qualified person install according to circuit diagram and
Auxiliary Power Guidelines (see
Section 11).
93
Remove plug
before inserting
leads. Reinstall
bushing.
91
Remove auxiliary power panel
mounting screws. Tilt panel forward.
90
3
Lead 93
4
Lead 92
5
Lead 91
6
Lead 42 (Circuit Grounding
Lead)
7
Lead 90 (Neutral)
92
4
Rear Of Panel
5
91
92
93
3
6
2
12
8
Isolated Neutral Terminal
9
Jumper Lead 42
10 Grounding Terminal
7
Jumper 42 is connected to lead 90 at
factory. Jumper 42 may be disconnected from neutral to meet applicable electrical codes.
10
Lead 42 connects to front panel
Ground stud.
11
Close
panel
opening if no
connections
are made to
power plant.
9
120V
1-Phase
120V
Tools Needed:
240V
3-Phase
240V
240V
11 User-Supplied Leads
12 Circuit Breaker CB7 User
Terminals
Connect user-supplied leads to terminals on CB7.
Circuit
240V
8
Circuit Breaker CB7
breaker CB7 protects
single-phase receptacle RC5
and the load wires from overload.
If CB7 opens, all auxiliary power
plant output stops and the receptacle does not work.
Reinstall auxiliary power panel.
Ref. 197 399 / 802 332-E
OM-496 Page 37
7-3. Optional Auxiliary Power Receptacles
1
120 V 20 A AC GFCI
Receptacle GFCI1
2
240 V 15 A AC European
Receptacle RC1
3
240 V 15 A AC Australian
Receptacle RC1
4
240 V 15 A AC South African
Receptacle RC1
5
240 V 15 A AC British
Receptacle RC1
European Receptacle
6
1
2
7
Receptacles supply 60 Hz singlephase power at weld/power speed.
If a ground fault is detected, the
GFCI Reset button pops out and
the receptacle does not work.
Check for faulty tools plugged in
receptacle. Press button to reset
GFCI1.
At least once a month, run en-
Australian Receptacle
6
1
gine at weld/power speed and
press test button to verify GFCI
is working properly.
3
7
6
Circuit Breaker CB2
7
Circuit Breaker CB3
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Place button to reset breaker.
CB3 protects RC1 from overload. If
CB3 opens, RC1 does not work.
Place button to reset breaker.
If a circuit breaker continues to
open, contact Factory Authorized Service Agent.
Auxiliary power is not affected
South African Receptacle
by weld output.
6
1
4
7
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all receptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
British Receptacle
6
1
5
7
191 624
OM-496 Page 38
SECTION 8 – MAINTENANCE & TROUBLESHOOTING
8-1. Maintenance Labels
For Non-CE Products
For CE Products Only
OM-496 Page 39
8-2. Routine Maintenance
Note
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Stop engine before maintaining.
Recycle engine
fluids.
See also Engine Manual and Mainte-
nance Label. Service unit more often if
used in severe conditions.
*
To be done by Factory Authorized
Service Agent.
8h
Coolant
Full
Wipe
Up
Spills.
Check Fluid
Levels. See
Section 4-7.
OIL
Full
FUEL
WATER
Drain Water
From Fuel
System.
50 h
Clean And
Tighten
Weld
Terminals.
Clean Air Filter.
See Section 8-3.
100 h
Clean And
Tighten
Battery
Connections.
Check air cleaner
hoses for cracks
and loose clamps.
200 h
Replace
Unreadable
Labels.
1/2 in.
(13 mm)
Check Belt
Tension.
250 h
Change Oil. See
Section 8-7.
Change Oil
Filter. See
Section 8-7.
Check And
Clean Spark
Arrestor. See
Section 8-4.
400 h
Change Fuel
Filters. See
Section 8-7.
OM-496 Page 40
Check
Valve
Clearance.*
Check Radiator
Fluid Level. See
Section 4-7.
500 h
Repair Or
Replace
Damaged
Cables.
800 h
Clean/Set
Injectors.*
1000 h
OR
Blow Out Or
Vacuum Inside.
During Heavy
Service,
Clean Monthly.
FUEL
SLUDGE
Drain Sludge
From Fuel
Tank. See
Section 8-7.
Service Welding Generator
Brushes And Slip Rings. Service
More Often In Dirty Conditions.*
Notes
OM-496 Page 41
8-3. Servicing Air Cleaner
Stop engine.
1
2
3
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.
4
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.
5
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.
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.
Keep nozzle
2 in (51 mm)
from element.
1
Housing
2
Safety Element (Optional)
3
Primary Element
4
Dust Cap
5
Dust Ejector
To clean air filter:
Blow
Inspect
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 – ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 197 784
OM-496 Page 42
8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler
Stop engine and let cool.
1
Spark Arrestor Muffler
2
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3
Exhaust Pipe
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
Stop engine and let cool.
3
2
Reinstall cleanout plug.
1
Tools Needed:
3/8 in
802 160-D / Ref. 197 784
OM-496 Page 43
8-5. Adjusting Engine Speed On Standard Models
Stop engine and let cool.
Engine Speed
(No Load)
RPM (Hz)
Weld/Power
1850 (61.7)
Maximum
Engine speed is factory set and
should not require adjustment. After tuning engine, check engine
speed with tachometer or frequency meter. See table for proper no
load speed. If necessary, adjust
speed as follows:
Start engine and run until warm.
On CC Models, place Stick/TIG
switch in Stick position.
On CC/CV models, turn Process/
Contactor switch to Stick – Electrode Hot position.
1 Lock Nut
2 Adjustment Screw
3
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
Do not set engine speed higher
than specified.
3
Engine Stop Lever
Use lever to stop engine if Engine
Control switch does not work.
Stop engine.
Close door.
2
1
Tools Needed:
10 mm
802 490-D / 802 491
OM-496 Page 44
8-6. Adjusting Engine Speed On Models With Automatic Idle (Optional)
Engine Speed
(No Load)
1850 rpm max
(61.6 Hz)
1250 rpm
(41.6 Hz)
After tuning engine, check engine speed
with tachometer or frequency meter.
See table for proper no load speed. If
necessary, adjust speed as follows:
Start engine and run until warm.
On CC models, place Stick/TIG switch
in Stick position.
On CC/CV models, turn Process/Contactor switch to Stick – Electrode Hot
position.
Idle Speed Adjustment
1
Throttle Rod/Plunger
2
Locknut
Loosen locknut. Place Engine Control
switch in Run/Idle position.
Turn throttle rod and plunger until engine
runs at idle speed. Tighten locknut.
Be sure solenoid plunger pulls all
the way in (“bottoms”) when energized.
It may be necessary to move the
linkage to the other hole in throttle
bracket to set idle speed correctly.
Weld/Power Speed Adjustment
3
Engine Weld/Power Speed
Adjustment Screw
4
Locknut
Place Engine Control switch in Run position.
3
Loosen locknut. Turn screw until engine
runs at weld/power speed. Tighten locknut.
Do not set engine speed higher than
specified.
Stop engine.
4
If necessary,
move linkage to
other hole in
bracket to set idle
speed correctly.
1
2
802 538-A
OM-496 Page 45
8-7. Servicing Fuel And Lubrication Systems
Stop engine and let cool.
After servicing, start engine
and check for fuel leaks.
Stop engine, tighten connections as necessary, and wipe
up spilled fuel.
4
3
1
2
3
Oil Filter
Oil Drain Valve And Hose
Oil Fill Cap
4
Fuel Line
5
Primary Fuel Filter (Fuel/
Water Separator)
6
Petcock
7
Secondary Fuel Filter
8
Fuel Tank Sludge Drain Valve
7
5
6
To change oil and filter:
1
Route oil drain hose and valve
through hole in base. See engine
manual and engine maintenance
label for oil/filter change information.
To drain water from fuel system:
Open primary fuel filter petcock and
drain water into metal container.
Close petcock when water-free fuel
flows.
To replace primary fuel filter:
Turn filter counterclockwise. Remove filter.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new filter. Install new filter and turn clockwise. Bleed air from fuel system according to engine manual.
Inspect fuel lines, and replace if
cracked or worn.
To replace secondary fuel filter:
2
See engine manual.
To drain sludge from fuel tank:
8
Put metal container under drain, and use screwdriver to open sludge
drain valve. Close valve when
sludge has drained.
Close door.
Tools Needed:
802 490-D / Ref. 801 434
OM-496 Page 46
8-8. Overload Protection
Stop engine.
When a circuit breaker or fuse
opens, it usually indicates a
more serious problem exists.
Contact Factory Authorized
Service Agent.
1
2
Fuse F1
Fuse F2
F1 and F2 protect the stator exciter
winding from overload. If F1 opens,
weld and auxiliary power is low or
stops entirely. If F2 opens, weld output is low or stops entirely. 4 kVA/
kW auxiliary power is still available.
2
7
6
5
3
1
3
Circuit Breaker CB6
(CC/CV Models Only)
4
Circuit Breaker CB10 (Not
Shown)
5
Circuit Breaker CB11
6
Circuit Breaker CB12
7
Circuit Breaker CB13
CB6 protects the 24 and 115 volt ac
output to remote receptacle RC14,
and 24 volt output to field current
regulator board PC1 (CC/CV models only). If CB6 opens, weld output
and 24 and 115 volt output to RC14
stops.
CB10 protects the engine battery
circuit. If CB10 opens, the engine
will not crank. CB10 automatically
resets when the fault is corrected.
CB11 protects the engine wiring
harness. On CC models, if CB11
opens the max OCV circuit does
not work and open circuit voltage is
variable at all times (see max OCV
note under Weld Controls in Section 5-2). If CB11 opens on CV models, weld output stops (auxiliary
power is still available).
CB12 protects the field flashing circuit. If CB12 opens, the generator
may not excite at start-up and weld
and auxiliary power output may not
be available.
CB13 protects the engine shutdown circuit. If CB13 opens, the engine cranks but does not start.
Press button to reset breaker.
802 170-D / Ref. 802 168-D
OM-496 Page 47
8-9. Diagnosing Causes Of Engine Fault Shutdowns
Use the front panel engine lights to
help determine the cause of an automatic engine shutdown.
Correct the cause of the shut-
Pre-Start Diagnostic Checks
down before operating the
welding generator.
This unit does not have a battery charging fault shutdown.
The engine continues to run if
the Battery Charging Light
goes on.
Turn Engine Control Switch To Run/Idle
Position While Pressing Magnetic
Shutdown Switch.
Normal Condition:
Oil Pressure Light On;
Battery Charging, Fuel, And Temperature Lights Off.
If Oil Pressure Light Is Off, See Factory Authorized Service Agent.
If Battery Charging Light Is On, Have Factory Authorized Service Agent
Check Alternator.
If Temperature Light Is On, Correct Cause Of Overheating
(See Engine Manual).
If Engine Is Okay, See Factory Authorized Service Agent.
If Fuel Light Is On, Check Fuel Level.
If Fault Continues, See Factory Authorized Service Agent.
Diagnostic Checks While Running
20s
Start Engine (With No Load Applied).
Continue Pressing Shutdown Switch
Until Engine Lights Go Off.
Normal Condition:
Engine Lights Go Off As Engine Reaches
Normal Operating Condition.
Lights That Stay On After 20 Sec. Indicate Fault
Condition.
Stop Engine And Correct Fault (See Above) If Fault
Continues, See Factory Authorized Service Agent.
Ref. 197 784
OM-496 Page 48
8-10. Troubleshooting
A. Welding – CC Models
Trouble
Remedy
No weld output; auxiliary power output Check position of Ampere Range switch.
okay.
Check position of optional polarity switch.
Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
control to Remote Amperage Adjust receptacle RC13 (see Sections 4-10 and 5-1).
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 4-10).
Check fuse F2, and replace if open (see Section 8-8). Have Factory Authorized Service Agent check integrated rectifier SR2 and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
No weld output or auxiliary power output. Disconnect equipment from auxiliary power receptacles during start-up.
Check fuses F1 and F2, and replace if open (see Section 8-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (see Section 8-8).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output.
Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
High weld output.
Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent check OCV control circuit.
Low weld output.
Check engine speed, and adjust if necessary.
Check fuses F1 and F2, and replace if open (see Section 8-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
Maximum weld output only in each Have Factory Authorized Service Agent check control relay CR7.
ampere range (with Stick/TIG Selection
switch in Stick position).
No remote fine amperage control.
Place Amperage Adjust switch in correct position.
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 4-10).
Reset circuit breaker CB11 (see Section 8-8). Have Factory Authorized Service Agent check control relay
CR7.
Repair or replace remote control device.
Have Factory Authorized Service Agent check OCV control circuit.
OM-496 Page 49
B. Welding – CC/CV Models
Trouble
Remedy
No weld output; auxiliary power output Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and
okay.
connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 4-11 and 6-1).
Check position of Ampere Range switch.
Check position of optional polarity switch.
Reset circuit breaker CB11 (see Section 8-8).
Reset circuit breaker CB6 (see Section 8-8). Check for faulty remote device connected to RC14.
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).
Have Factory Authorized Service Agent check connector board PC6 and connections.
Check fuse F2, and replace if open (see Section 8-8). Have Factory Authorized Service Agent check
brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor.
No weld output or auxiliary power output. Disconnect equipment from auxiliary power receptacles during start-up.
Check fuses F1 and F2, and replace if open (see Section 8-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output.
Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
High weld output.
Check position of Ampere Range switch and Voltage/Amperage Adjust control.
Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent check field current regulator board PC1.
Low weld output.
Check engine speed, and adjust if necessary.
Check fuses F1 and F2, and replace if open (see Section 8-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position.
control.
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).
Repair or replace remote control device.
Constant speed wire feeder does not Reset circuit breaker CB6 (see Section 8-8).
work.
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).
Repair or replace wire feeder.
Low CV weld output.
Set Ampere Range switch to highest range.
Min or max CV weld output only.
Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.
Repair or replace remote control device.
Have Factory Authorized Service Agent check field current regulator board PC1.
OM-496 Page 50
C. Standard Auxiliary Power
Trouble
Remedy
No auxiliary power output; weld output Reset receptacle circuit breakers.
okay.
No auxiliary power or weld output.
Disconnect equipment from auxiliary power receptacles during start-up.
Check fuses F1 and F2, and replace if open (see Section 8-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, and the rotor.
Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (CC models) or field
current regulator board PC1 (CC/CV models) (see Section 8-8).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output
receptacles.
at
auxiliary
power Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent adjust auxiliary power field current resistor R3.
Low output
receptacles.
at
auxiliary
power Check engine speed, and adjust if necessary.
Check fuse F1, and replace if open (see Section 8-8). Have Factory Authorized Service Agent check integrated rectifier SR1, resistor R3, and capacitor C9.
D. Optional Auxiliary Power Plant
Trouble
No or low output at optional auxiliary
power plant/receptacle RC5
(CC/CV models only).
Remedy
Place Process/Contactor switch in Electrode Hot - Stick position (see Section 6-3).
Reset circuit breaker CB7(see Section 7-2).
Check engine weld/power speed, and adjust if necessary (see Section 8-5).
Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
PC1.
High output at optional auxiliary power
plant/receptacle RC5 (CC/CV models
only).
Check engine weld/power speed, and adjust if necessary (see Section 8-5).
Have Factory Authorized Service Agent check field current regulator board PC1.
E. Engine
Trouble
Engine will not crank.
Remedy
Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8-8).
Have Factory Authorized Service Agent check engine wiring harness and components.
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check Engine Control switch S1.
Engine cranks but does not start.
Press Magnetic Shutdown switch MS1 when starting engine.
Check fuel level.
Reset circuit breaker CB13 (see Section 8-8). Have Factory Authorized Service Agent check enginewiring harness and components.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check control relay CR2, and fuel solenoid FS1.
Air in fuel system. See engine manual.
OM-496 Page 51
Trouble
Remedy
Engine starts, but stops when Magnetic When starting engine, continue holding Magnetic Shutdown switch until after engine indicator lights go
Shutdown switch is released.
out.
Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Sections 4-7 and 8-9).
Engine hard to start in cold weather.
Use starting aid switch (see Section 5-1 or 6-1).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 8-1).
Engine suddenly stops.
Check fuel, oil, and coolant levels. Automatic shutdown system stops engine if fuel level or oil pressure
is too low, or coolant temperature is too high (see Sections 4-7 and 8-9).
See engine manual.
Engine slowly stopped and cannot be
restarted.
Check fuel level.
Check engine air and fuel filters (see Sections 8-3 and 8-7).
See engine manual.
Battery discharges between uses.
Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine idles, but does not come up to
weld speed (models with idle option
only).
Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1.
Check for obstructed throttle solenoid.
Engine does not run at idle speed
(models with idle option only).
Place Stick/TIG Selection switch (CC models) or Process/Contactor switch (CC/CV models) in Stick
or MIG position.
Check for obstructed throttle solenoid.
Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.
Engine uses oil during run-in period; Dry engine (see Section 10).
wetstacking occurs.
OM-496 Page 52
Notes
OM-496 Page 53
SECTION 9 – ELECTRICAL DIAGRAMS
Figure 9-1. Circuit Diagram For CC Welding Generator
OM-496 Page 54
201 219
OM-496 Page 55
Figure 9-2. Circuit Diagram For CC/CV Welding Generator
OM-496 Page 56
201 218
OM-496 Page 57
SECTION 10 – RUN-IN PROCEDURE
run_in1 6/96
10-1. Wetstacking
1
Welding Generator
Run diesel engines near rated output during run-in period to properly
seat piston rings and prevent wetstacking. See nameplate or rating
label to find rated output.
2
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.
1
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-496 Page 58
10-2. 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.
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.
4
2
1
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe
correct
polarity.
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator A/V control so load
equals rated generator output (see
nameplate).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
3
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-496 Page 59
10-3. 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.
1 Resistance Grid
Use grid sized for generator rated
output.
Turn Off grid.
6
1
2
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.
Start engine and run for several
minutes.
3
5
Set grid switches and then adjust
generator A/V control so load
equals rated generator output (see
nameplate).
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
4
+
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-496 Page 60
SECTION 11 – AUXILIARY POWER GUIDELINES
11-1. Selecting Equipment
1
2
3
Auxiliary Power Receptacles
– Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577
11-2. Grounding Generator To Truck Or Trailer Frame
1
2
3
4
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
3
1
4
GND/PE
OR
2
2
Electrically bond generator
frame to vehicle frame by
metal-to-metal contact.
S-0854
OM-496 Page 61
11-3. Grounding When Supplying Building Systems
1
1
2
2
GND/PE
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Use ground device as stated
in electrical codes.
2
3
ST-800 576-B
11-4. 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 11-8).
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-496 Page 62
11-5. 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
11-6. 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
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
OM-496 Page 63
11-7. 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
OM-496 Page 64
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
11-8. 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
11-9. 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-496 Page 65
11-10. Typical Connections To Supply Standby Power
1
2
3
Obtain and install correct switch.
Switch rating must be same as or
greater than the branch overcurrent
protection.
Customer-supplied equipment is required if
generator is to supply standby power during
emergencies or power outages.
4
1
240 V
6
Neutral
120 V
2
Extension Cord
Select as shown in Section 11-11.
120 V
3
Generator Connections
Connect terminals or plug of adequate amperage capacity to cord.
Follow all applicable codes and
safety practices.
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.
240 V
120 V
Load
Circuit Breakers or Fused
Disconnect Switch
Obtain and install correct switch.
5
120/240 Volt
60 Hz
Three-Wire
Service
Power Company Service
Meter
Main and Branch Overcurrent
Protection
Double-Pole, Double-Throw
Transfer Switch
120 V
7
Load Connections
4
7
CB
Item 4 is not necessary if circuit
protection is already present in
welding generator auxiliary
power output circuit.
or
F1
6
5
240 V
120/240 Volt
Single-Phase
Three-Wire
Generator Output
Connection
120 V
120 V
Ground
S-0405-A
OM-496 Page 66
11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
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
6
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-496 Page 67
SECTION 12 – PARTS LIST
Hardware is common and
not available unless listed.
14
13
12
3
11
2
1
16
15
10
19
17
22
20
9
18
4
8 (CV)
23
5
6
6
24
25
7
26
28
27
29
123 (CV)
30
122 (CV)
31
33
32
34
35
121 (Fig. 12–5)
108 (CV)
120
107 (CV)
103
109 (CV)
110 (CC Only)
111
104
112 (CC Only)
115
119–(Fig. 12–4 or 12–5)
105
113 (CC Only)
118
117
106
116
114
Figure 12-1. Main Assembly
OM-496 Page 68
124
41
42
38
39
40
63
37
64
62
36
65
61
66
43
56
53
54
60
59
47
44
45
46
48
67
57
23
68
69
55
58
49
50
70
71
99
51 100–(Fig. 12–4)
88
89
73
74
75
90
103
91
52
98
9
102
92
93
94
95
96
72
76
80
77
78
79
68
87
82
83
84
101–(Fig. 12–2 or 12–3)
85
86
802 550-C
OM-496 Page 69
81
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 189 824
. . . 2 . . . . . . . . . . . . . 191 623
. . . 2 . . . . . . . . . . . . . 176 106
. . . 3 . . . . . . . . . . . . +189 828
. . . 4 . . . . . Z1 . . . . 197 565
. . . 5 . . . . . 1T . . . . 038 621
. . . . . . . . . . . . . . . . . . . 038 620
. . . . . . . . . . . . . . . . . . . 197 736
. . . . . . . . . . PLG3 . . . 166 680
. . . . . . . . . . . . . . . . . . . 187 654
. . . . . . . . . . PLG6 . . . 141 270
. . . 6 . . . . . . . . . . . . . 081 499
. . . 7 . . . . . . . . . . . . . 188 600
. . . 8 . . . . . T1 . . . CV192 371
. . . 9 . . . . . . . . . . . . . 173 352
. . . 10 . . . . . . . . . . . . . 189 708
. . . 11 . . . . . . . . . . . . . 191 307
. . . 12 . . . . . . . . . . . . . . 189618
. . . 13 . . . . . . . . . . . . . 198 457
. . . 14 . . . . . . . . . . . . . 173 036
. . . . . . . . . . . . . . . . . . . 010 863
. . . 15 . . . . . . . . . . . . . 189 763
. . . 16 . . . . . . . . . . . . . 189 764
. . . . . . . . . . . . . . . . . . . *192 938
. . . . . . . . . . . . . . . . . *♦192 939
. . . 17 . . . . . . . . . . . . . 189 464
. . . 18 . . . . . . . . . . . . . 197 608
. . . 19 . . . . . . . . . . . . . 189 701
. . . 20 . . . . CR8 . . . 155 309
. . . 21 . . . . . . . . . . . . . . Deleted
. . . 22 . . . . . . . . . . . . . 191 819
. . . . . . . . . . . . . . . . . . . 198 584
. . . 23 . . . . . . . . . . . . . 095 636
. . . 24 . . . . . . . . . . . . . 192 750
. . . 25 . . . . . . . . . . . . . *192 744
. . . 26 . . . . . . . . . . . . . 192 741
. . . 27 . . . . . . . . . . . . . 201 658
. . . 28 . . CR1, CR2 . 090 104
. . . . . . . . . . . . . . . . . . . 197 690
. . . 29 . . . . . 6T . . . . 190 210
. . . 30 . . . D8/C8 . . 189 701
. . . 31 . . . . CB10 . . . 190 374
. . . . . . . . . . . . . . . . . . . 148 850
. . . . . . . . . . PLG7 . . . 168 071
. . . . . . . . . . PLG4 . . . 166 680
. . . . . . . . . . . . . . . . . . . 187 654
. . . . . . . . . . . . . . . . . . . 187 651
. . . 32 . . . . . . . . . . . . . 190 196
. . . 33 . . . . . . . . . . . . +189 154
. . . 34 . . . . . . . . . . . . . 196 220
. . . 35 . . . . . . . . . . . . . 192 362
. . . 36 . . . . . . . . . . . . +193 684
. . . 37 . . . . . . . . . . . . . 189 052
. . . 38 . . . . . . . . . . . . . 190 198
. . . 39 . . . . . . . . . . . . . 192 041
. . . 39 . . . . . . . . . . . . . 176 103
. . . 40 . . . . . . . . . . . . . 108 487
. . . 40 . . . . . . . . . . . . . 176 104
. . . 41 . . . . . . . . . . . . . 105 734
OM-496 Page 70
. . PANEL, gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning all panels must be in place while running . . . . . . . . . . . . . 2
. . LABEL, warning moving parts (CE models only) . . . . . . . . . . . . . . . . . . . . . 2
. . PANEL, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BLOCK, term 30A 4 pole frict term str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . HARNESS, unit weld control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, (kit) rect univ 084 12P/S 3 row plug cable . . . . . . . . . . 1
. . . . SEAL, wire univ 12P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, (kit) rect univ 084 4P/S 1 row plug cable lkg . . . . . . . . . 1
. . BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FRAME, mtg reactor and rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . XFMR, 115V pri 24vct 8A w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 3ft
. . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . COVER, plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TUBE, air intake perkins 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOSE, elbow air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CLAMP, hose 1.125 – 3.000 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, mounting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . CONTACTOR, solenoid 12VDC cont 400A inrush . . . . . . . . . . . . . . . . . . . . 1
....................................................................
. . HOSE, sae .312 id x .560 od x 14.000 (order by ft) . . . . . . . . . . . . . . . . . . 2
. . HOSE, sae .312 id x .560 od x 5.000 (order by ft) . . . . . . . . . . . . . . . . . . . . 1
. . HOSE, sae .187 id x .41 od x 30.000 (order by ft) . . . . . . . . . . . . . . . . . . . 1
. . BASE, fuel filter w/adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FILTER, fuel spin-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BLOCK, spacer mtg filter base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FRAME ASSEMBLY, center upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 2
. . HARNESS, engine control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . 1
. . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg . . . . . . . . . 1
. . . . CONNECTOR, (kit) rect univ 084 12P/S 3 row plug cable lkg . . . . . . . . 1
. . . . SEAL, wire univ 12P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, hold down fuel tank rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, mtg nyl 1/2 conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . GROMMET, plastic neck filler fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CAP, tank screw-on 3.500 in w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, use diesel fuel only (CE models only) . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . LABEL, warning falling equipment (CE models only) . . . . . . . . . . . . . . . . . 2
. . PIPE, muffler extension elbow 1.875 od . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . . 42 . . . . . . . . . . . . . 191 176 . . PLUG, radiator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . . . 191 354 . . SUPPORT, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 44 . . . . . . . . . . . . . 189 245 . . TANK, fuel 23gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 45 . . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 084 173 . . . . CLAMP, hose .460 – .545clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . . . . 189 912 . . . . FITTING, stl barbed elbow w/.047 in orf zinc pld . . . . . . . . . . . . . . . . . . .
. . . 47 . . . . . . . . . . . . . 189 909 . . . . FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc . . . . . . . . . . . . . . .
. . . 48 . . . . . . . . . . . . . 189 913 . . . . FITTING, stl barbed elbow zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 49 . . . . . . . . . . . . . 190 142 . . . . SENDER, fuel gauge 9.7500 deep tank . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . . 189 910 . . . . FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc . . . . . . . . . . . . .
. . . 51 . . . . . . . . . . . . . 189 908 . . . . VALVE, drain fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 52 . . . . . . . . . . . . . 181 572 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 53 . . . . . . . . . . . . . 010 875 . . CLAMP, muffler 2.000 dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 54 . . . . . . . . . . . . . 197 494 . . MANIFOLD, exhaust muffler perkins 104.22 . . . . . . . . . . . . . . . . . . . . . . . .
. . . 55 . . . . . . . . . . . . . 197 485 . . ENGINE, Perkins dsl elec 104.22bw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 192 664 . . HOSE, pvc .500 id x .750 od x 10.000 (order by ft) . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 198 694 . . FTG, hose poly barbed 5/8id x 1/2id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 023 562 . . CLAMP, hose .312 – .875 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *197 899 . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *192 744 . . FILTER, fuel spin-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *197 997 . . FILTER, fuel secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *199 374 . . SWITCH, coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *199 373 . . SWITCH, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 56 . . . . . . . . . . . . . 197 995 . . GUARD, belt perkins 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 57 . . . . . . . . . . . . . 197 495 . . HOSE, radiator upper perkins 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 58 . . . . . . . . . . . . . *197 944 . . BELT, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 59 . . . . . . . . . . . . +197 734 . . GUARD, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 60 . . . . . . . . . . . . . 197 505 . . RADIATOR, w/shroud and 7# cap 3 row core . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 605 982 . . CAP, radiator pressure 7 lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 147 923 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 61 . . . . . . . . . . . . . 189 717 . . UPRIGHT, rear Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 62 . . . . . . . . . . . . . 190 207 . . CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng . . . . . . . . . . . . .
. . . 63 . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . .
. . . 64 . . . . . . . . . . . . . 190 206 . . CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng . . . . . . . . . . . . .
. . . 65 . . . . . . . . . . . . . 190 897 . . BATTERY, stor 12V 650crk 110rsv gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 66 . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 66 . . . . . . . . . . . . . 176 108 . . LABEL, warning battery explosion can blind (CE models only) . . . . . . . . .
. . . 67 . . . . . . . . . . . . +189 290 . . BATTERY BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 68 . . . . . . . . . . . . . 191 626 . . BUMPER, door engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 69 . . . . . . . . . . . . . 189 293 . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 70 . . . . . . . . . . . . . 197 496 . . HOSE, radiator lower perkins 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 199 505 . . HOSE, oil drain assy 32 in (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 71 . . . . . . . . . . . . . 165 271 . . . . VALVE, oil drain 3/8-18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 72 . . . . . . . . . . . . . 176 529 . . . . FITTING, hose brs barbed fem 1/2tbg x 3/8NPT . . . . . . . . . . . . . . . . . . .
. . . 73 . . . . . . . . . . . . . . 113 854 . . . . HOSE, SAE .500 ID x .780 OD xc oil (order by ft) . . . . . . . . . . . . . . . . . .
. . . 74 . . . . . . . . . . . . . 197 448 . . FITTING, hose brs barbed elbow m 1/2 tbg x 3/8 npt . . . . . . . . . . . . . . . . .
. . . 75 . . . . . . . . . . . . . . . . . . . . . . . . WASHER, oil drain (available through engine manufacturer) . . . . . . . . . . .
. . . 76 . . . . . . . . . . . . . 197 196 . . FITTING, adapter oil drain 12mm male x 3/8 npt female . . . . . . . . . . . . . .
. . . 77 . . . . . . . . . . . . . 190 190 . . TANK, coolant recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 78 . . . . . . . . . . . . . 199 592 . . LATCH, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 78 . . . . . . . . . . . . ♦190 126 . . LATCH, paddle series 20 (stainless steel) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 79 . . . . . . . . . . . . +189 825 . . DOOR, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 80 . . . . . . . . . . . . . 190 992 . . KEEPER, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 81 . . . . . . . . . . . . . 190 076 . . CHANNEL, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 82 . . . . . . . . . . . . . 087 341 . . BUMPER, door 1.000 OD x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 83 . . . . . . . . . . . . . 189 975 . . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 84 . . . . . . . . . . . . . 189 826 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 85 . . . . . . . . . . . . . 190 518 . . LABEL, diesel engine maintenance Perkins . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
4
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
4
1
1
1
1
1
3ft
1
1
1
1
1
1
1
1
1
2
2
1
1
OM-496 Page 71
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . . 85 . . . . . . . . . . . . . 200 778 . . LABEL, diesel engine maintenance Perkins (CE models only) . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . 189 827 . . PANEL, gen RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . 190 572 . . STIFFENER, engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . 199 849 . . SCREW, 625-11 x 4.00hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 89 . . . . . . . . . . . . . 071 731 . . WASHER, flat .656 ID x 2.250 OD x .187T stl pld . . . . . . . . . . . . . . . . . . . . 4
. . . 90 . . . . . . . . . . . . . 197 489 . . BRACKET, mtg RH Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 197 488 . . BRACKET, mtg LH Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 92 . . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 93 . . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 . . . . . . . . . . . . . . . . . . 4
. . . 94 . . . . . . . . . . . . . 135 205 . . NUT, 625-11 .94hex .76H stl pld elastic stop nut . . . . . . . . . . . . . . . . . . . . . 4
. . . 95 . . . . . . . . . . . . . *197 997 . . FILTER, fuel secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . . . . . . . . . . . . . . . . . . . . PUMP, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . . . . 173 909 . . HOSE, sae .312 id x .560 od (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . . . . . . . . 198 548 . . BRACKET, mtg fuel filter/pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 99 . . . . . . . . . . . . . 176 106 . . LABEL, warning moving parts (CE models only) . . . . . . . . . . . . . . . . . . . . . 2
. . 100 . . . . . . . . . Figure 12-6 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . Figure 12-2, Figure 12-3 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . . 189 731 . . FIREWALL, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . 191 446 . . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . . . 6ft
. . 104 . . . . . . . . . . . . 190 250 . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 104 . . . . . . . . . . . . 200 864 . . LABEL, warning do not weld on base (CE models only) . . . . . . . . . . . . . . . 2
. . 105 . . . . . . . . . . . . 191 512 . . BRACKET, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . . 191 897 . . BRACKET, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 107 . . . . . . . . . . . CV193 138 . . BRACKET, mtg circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . CV190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . CV193 185 . . HARNESS, transformer (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . CB6 . . CV083 432 . . . . CIRCUIT BREAKER, man reset 1P 10A 250VAC frict . . . . . . . . . . . . . . 1
. . . . . . . . . . RC11 . . CV167 640 . . . . CONNECTOR, (kit) rect univ 084 4p/s 1 row rcpt cable/panel lkg . . . . . 1
. . 110 . . . . R4 . . . CC191 292 . . RESISTOR, WW fxd 375W 50 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . . . R3 . . . . 189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . 112 . . . . R2 . . . CC189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . 113 . . . . R5 . . . CC189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . 114 . . . . . . . . . . . . 190 179 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 115 . . . . . . . . . . . . 190 058 . . NUT, .250-20 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . 049 525 . . NUT, 312-18 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . 116 . . . . . . . . . . . +188 946 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 117 . . . . . . . . . . . . 190 010 . . LABEL, caution do not use ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 117 . . . . . . . . . . . . 176 109 . . LABEL, caution do not use ether (CE models only) . . . . . . . . . . . . . . . . . . . 1
. . 118 . . . . . . . . . . . . 134 792 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 118 . . . . . . . . . . . . 176 105 . . LABEL, warning general precautionary (CE models only) . . . . . . . . . . . . . 1
. . 119 . . . . . Figure 12-4, Figure 12-5 PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 120 . . . . . . . . . . . . 191 448 . . TOP, cover front upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 121 . . . . . . . . . Figure 12-7 . . MAIN RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 122 . . . . . . . . . . . CV193 453 . . BRACKET, mtg box fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 123 . . . PC1 . . CV189 143 . . MODULE, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 124 . . . . . . . . . . . . 176 230 . . LABEL, warning hot exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 190 469 . . KIT, label (includes safety and informational labels) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 061 . . KIT, label (includes safety and informational labels) (CE models only) . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 190 469 or Label Kit 201 061 (CE models only).
*Recommended Spare Parts.
C
C CC models only.
C
V CC/CV models only.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement
Parts. Model and serial number required when ordering parts from your local distributor.
OM-496 Page 72
15
8
7
6
5
14
13
4
3
2
1
9
10
11
12
802 551-A
Figure 12-2. Control Box Assembly – CC Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-2. Control Box Assembly – CC Models (Figure 12-1 Item 101)
. . . 1 . . . F1, F2 . . *085 874
. . . 2 . . . . . . . . . . . . . 046 432
. . . 3 . . . . . . . . . . . . . 189 385
. . . 4 . . . . C12 . . . 191 944
. . . . . . . . . . . . . . . . . . . 197 712
. . . 5 . . . . CR9 . . . . 113 247
. . . 6 . . . . CR7 . . . 188 636
. . . 7 . . . D1/C1 . . 189 701
. . . 8 . . SR1, SR2 . 035 704
. . . 9 . . . . CR5 . . . 090 104
. . . 10 . . . . 2T, 3T . . 190 210
. . . . . . . . . . RC5 . . . 147 663
. . . . . . . . RC3, RC4 . 166 679
. . . . . . . RC1, 2, 7 . 168 071
. . . 11 CB11, 12, 13 139 266
. . . 12 . . . . . . . . . . . . . 194 483
. . . 13 . . . . . . . . . . . . . 177 136
. . . 14 . . . . . C9 . . . . . 087 110
. . . 15 . . . . . R6 . . . . 141 424
. . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, polyp met film 10. uf 250 vac 10% . . . . . . . . . . . . . . . . . . . .
. . HARNESS, control box, weld control (consisting of) . . . . . . . . . . . . . . . . .
. . . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . .
. . . . RELAY, OCV control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RELAY, encl 12VDC SPST 30A/15VDC . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, (kit) rect univ 084 15P/S 3 row rcpt cable/panel lkg . . .
. . . . CONNECTOR, (kit) rect univ 084 12P/S 3 row rcpt cable/panel lkg . . .
. . . . CONNECTOR, (kit) rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . .
. . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . .
. . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, ww fxd 30 w 25 ohm faston te . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
1
1
1
1
1
1
2
1
2
1
2
3
3
1
1
1
1
*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-496 Page 73
5
4
6
7
3
2
8
9
1
10
11
12
802 360
Figure 12-3. Control Box Assembly – CC/CV Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-3. Control Box Assembly – CC/CV Models (Figure 12-1 Item 101)
. . . 1 . . . F1, F2 . . *085 874
. . . 2 . . . . . . . . . . . . . 046 432
. . . 3 . . . . . . . . . . . . . 189 385
. . . 4 . . . . . . . . . . . . . 134 201
. . . 5 . . . . PC9 . . . 192 224
. . . 6 . . . . . C9 . . . . . 087 110
. . . 7 . . . . . . . . . . . . . 177 136
. . . . . . . . . . . . . . . . . . . 197 745
. . . 8 . . . . SR1 . . . 035 704
. . . 9 . . . . CR5 . . . 090 104
. . . 10 . . . . 2T, 3T . . 190 210
. . . . . . . . . . RC5 . . . 147 663
. . . . . . . . RC3, RC4 . 166 679
. . . . . . . RC1, 2, 7 . 168 071
. . . 11 CB11, 12, 13 139 266
. . . 12 . . . . . . . . . . . . . 194 483
. . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, support pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HARNESS, control box, cv weld control (consisting of) . . . . . . . . . . . . . . .
. . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RELAY, encl 12VDC SPST 30A/15VDC . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, (kit) rect univ 084 15P/S 3 row rcpt cable/panel lkg . . .
. . . . CONNECTOR, (kit) rect univ 084 12P/S 3 row rcpt cable/panel lkg . . .
. . . . CONNECTOR, (kit) rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . .
. . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . .
. . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
1
3
1
1
1
1
1
1
2
1
2
3
3
1
*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-496 Page 74
4
Hardware is common and
not available unless listed.
3
5
2
1
6
7
8
9
10
14
45
11
44
12
43
15
13
16
17
46
18
19
40
41
39
20
38
37
42
21
36
35
34
33
22
23
25
24
26
32
27
31
30
29
12
28
802 266-D
Figure 12-4. Panel, Front w/Components – CC Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-4. Panel, Front w/Components – CC Models (Figure 12-1 Item 119)
. . . 1 . . . . . . . . . . . . . 197 784 . . PLATE SCREENED, ident control rating; when ordering this item,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, screened (order by model and serial number) . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 191 359 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . S3 . . . . 189 382 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC6 . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . R1 . . . . 188 635 . . RHEOSTAT, WW 300W 34 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
OM-496 Page 75
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-4. Panel, Front w/Components – CC Models (Continued)
. . . . . . . . . . . . . . . . . . . 190 254
. . . 6 . . . . . S6 . . . . . 011 611
. . . 7 . . . . . S5 . . . . . 011 609
. . . 8 . . . . RC13 . . . 032 897
. . . . . . . . . . . . . . . . . . . 177 859
. . . . . . . . . . PLG2 . . . 168 071
. . . . . . . . . . . . . . . . . . . 187 651
. . . . . . . . . . . . . . . . . . . 201 045
. . . 9 . . . . . . . . . . . . . 191 308
. . . 10 . . . . PC8 . . . 189 744
. . . 11 . . . . . S1 . . . . 176 606
. . . 12 . . . . . . . . . . . . . 134 201
. . . . . . . . . . . . . . . . . . . 190 257
. . . 13 . . . . MS1 . . . 189 698
. . . 14 . . . . 4T, 5T . . 190 210
. . . 15 . . . . . S2 . . . . 021 467
. . . . . . . . . . . . . . . . . . . 135 275
. . . . . . . . . . . . . . . . . . . 153 501
. . . . . . . . . . . . . . . . . . . 187 655
. . . 16 . . . . CB1 . . . 201 083
. . . . . . . . . . . . . . . . . . . 201 553
. . . . . . . . . . . . . . . . . . . 201 109
. . . 17 . . . . CB2 . . . 093 996
. . . 18 . . . GFCI1 . . 151 981
. . . 19 . . . . RC1 . . . 147 632
. . . . . . . . . . . . . . . . . . . 201 053
. . . 17 . . . . CB2 . . . 093 996
. . . 17 . . . . CB3 . . . 139 266
. . . 18 . . . GFCI1 . . 151 981
. . . 19 . . . . RC1 . . . 176 355
. . . 20 . . . . . . . . . . . . . 190 861
. . . 20 . . . . . . . . . . . . . 200 910
. . . 21 . . . . . . . . . . . . +201 106
. . . 21 . . . . . . . . . . . . +201 052
. . . 22 . . . . . . . . . . . . . 083 030
. . . 23 . . . . . . . . . . . . . 601 836
. . . 24 . . . . . . . . . . . . ♦196 073
. . . 25 . . . . . S12 . . ♦195 825
. . . 26 . . . . . . . . . . . . . 201 125
. . . 27 . . PC4, PC5 . 189 744
. . . 28 . . . . . . . . . . . . . 039 046
. . . . . . . . . . . . . . . . . . . 180 735
. . . 29 . . . . . . . . . . . . . 181 169
. . . 30 . . . . . . . . . . . . . 186 621
. . . 31 . . . . . . . . . . . . ♦059 773
. . . 32 . . . . . . . . . . . . ♦010 647
. . . 33 . . . . . . . . . . . . . 039 047
. . . 34 . . . . . . . . . . . . . 193 260
. . . 35 . . . . . . . . . . . . . 193 258
. . . 36 . . . . . . . . . . . . . 190 323
. . . 37 . . . . . . . . . . . . . 193 143
. . . 38 . . . . . . . . . . . . . 021 385
. . . 39 . . . . . . . . . . . . . . 119 014
. . . 40 . . . . . PL1 . . . 191 241
. . . 41 . . . . FUEL . . . 191 242
. . . 42 . . . . . HM . . . . . 118 058
. . . 43 . . . . . . . . . . . . . 189 161
OM-496 Page 76
. . HARNESS, front panel weld control (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . SWITCH, tgl DPDT 15A 125VAC on-none-on spd term chr . . . . . . . . . .
. . . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr . . . . . . . . . .
. . . . RECEPTACLE, twlk grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, body 5 terminal (to engine control switch S1) . . . . . . . .
. . . . CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg . . . . . . . . .
. . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, receptacle twistlock (for RC13 – CE models only . . . . . . . . . . . .
. . BRACKET, terminal strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSEMBLY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HARNESS, front panel engine control (consisting of) . . . . . . . . . . . . . . . . .
. . . . SWITCH, magnetic manual reset low current . . . . . . . . . . . . . . . . . . . . . .
. . . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SWITCH, tgl SPST 3A 250V off-none-on spd term . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, (kit) rect univ 084 15P/S 3 row plug cable lkg . . . . . . . .
. . . . CONNECTOR, (kit) rect univ 039 6P/S 3 row . . . . . . . . . . . . . . . . . . . . . .
. . . . SEAL, wire univ 15P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT BREAKER, man reset 2P 20 A, 250VAC . . . . . . . . . . . . . . . . . . .
. . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HARNESS, auxiliary power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . .
. . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . .
. . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . .
. . HARNESS, auxiliary power (CE models only) (consisting of) . . . . . . . . . .
. . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . .
. . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . .
. . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . .
. . RECEPTACLE, str 2p3w 16a 220v flange mtg (CE models only) . . . . . . .
. . LABEL, warning electric shock and moving parts . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning, electric shock and moving parts (CE models only) . . . .
. . PANEL, aux pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, aux pwr (CE models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STUD, brs .250–20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, 250–20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSEMBLY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, receptacle 2.250 dia lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, receptacle GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOOT, magnetic shutdown switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LED, red 12V 4 ind lights panel mtg round . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GAUGE, fuel elec switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
12
1
1
2
1
1
5
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
2
1
2
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-4. Panel, Front w/Components – CC Models (Continued)
. . . 44 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . 148 723 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 192 505 or Label Kit 201 061 (CE models only).
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Hardware is common and
4
not available unless listed.
3
5
6
2
1
9
8
13
7
10
56
11
55
54
14
12
15
16
17
53
18
57
19
20
34
50
51
52
49
48
47
22
31
30
33
46
21
23
24
32
26
29
44
28
27
25
45
35
36
37
43
39
42
41
40
38
802 332-E
Figure 12-5. Panel, Front w/Components – CC/CV Models
OM-496 Page 77
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-5. Panel, Front w/Components – CC/CV Models (Figure 12-1 Item 119)
. . . 1 . . . . . . . . . . . . . 197 785 . . PLATE SCREENED, ident control; when ordering this item,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, screened (order by model and serial number) . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 191 359 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . S3 . . . . 189 382 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC6 . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . R1 . . . . . 193 118 . . POT, cp flat 1t 2w 1k ohm linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 193 159 . . HARNESS, front panel weld control CV (consisting of) . . . . . . . . . . . . . . .
. . . 6 . . . . . S6 . . . . 193 234 . . . . SWITCH, rotary 6 position gold contacts . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . S5 . . . . . 011 609 . . . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr . . . . . . . . . .
. . . . . . . . . PLG S1 . . 177 859 . . . . CONNECTOR, body 5 terminal (to engine control switch S1) . . . . . . . .
. . . . . . . . . . PLG9 . . . 193 183 . . . . CONNECTOR, rect cinch 18 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG10 . . 153 501 . . . . CONNECTOR, (kit) rect univ 039 6pp/s 3 row plug cable lkg . . . . . . . . .
. . . . . . . . . PLG14 . . 165 668 . . . . CONNECTOR, (kit) rect metrmate 10 skt 1 row plug/cable lkg . . . . . . .
. . . . . . . . . . PLG2 . . . 168 071 . . . . CONNECTOR, (kit) rect univ 084 9p/s 3 row plug cable lkg . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 187 651 . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG11 . . . 114 063 . . . . CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg . . . . . . . . . . . . . .
. . . 8 . . . . PC6 . . . 192 995 . . CIRCUIT CARD ASSY, connector/receptacle . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . 191 308 . . BRACKET, terminal strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . S1 . . . . 176 606 . . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 190 257 . . HARNESS, front panel engine control (consisting of) . . . . . . . . . . . . . . . . .
. . . 11 . . . . . S2 . . . . 021 467 . . . . SWITCH, tgl SPST 3A 250V off-none-on spd term . . . . . . . . . . . . . . . . .
. . . 12 . . . . MS1 . . . 189 698 . . . . SWITCH, magnetic manual reset low current . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . 4T, 5T . . 190 210 . . . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 135 275 . . . . CONNECTOR, (kit) rect univ 084 15P/S 3 row plug cable lkg . . . . . . . .
. . . . . . . . . . . . . . . . . . . 153 501 . . . . CONNECTOR, (kit) rect univ 039 6P/S 3 row . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 187 655 . . . . SEAL, wire univ 15P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . CB1 . . . 201 083 . . CIRCUIT BREAKER, man reset 2P 20 A, 250VAC . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 201 109 . . HARNESS, auxiliary power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . CB2 . . . 093 996 . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . .
. . . 16 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . .
. . . 17 . . . . RC1 . . . 147 632 . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 201 053 . . HARNESS, auxiliary power (CE models only) (consisting of) . . . . . . . . . .
. . . 15 . . . . CB2 . . . 093 996 . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . .
. . . . . . . . . . CB3 . . . 139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . .
. . . 16 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . .
. . . 17 . . . . RC1 . . . 176 355 . . RECEPTACLE, str 2p3w 16a 220v flange mtg (CE models only) . . . . . . .
. . . 18 . . . . RC5 . . ♦182 954 . . RCPT, str 3P4W 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . ♦025 248 . . STAND-OFF, insul .250-20 x 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . ♦604 102 . . CONNECTOR, clamp cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . ♦197 527 . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . ♦197 363 . . TERMINAL, ring tng screw clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . CB7 . . ♦196 780 . . CIRCUIT BREAKER, man reset 3p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . +201 106 . . PANEL, auxiliary power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . +201 052 . . PANEL, aux pwr (CE models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . +201 107 . . PANEL, auxiliary power (full kVA option) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . ♦196 781 . . BOOT, circuit breaker 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . ♦197 508 . . PLUG, protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . ♦077 440 . . BUSHING, conduit 1 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . 601 836 . . NUT, 250–20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . ♦197 291 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . 083 030 . . STUD, brs .250–20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . CT2 . . ♦197 433 . . TRANSFORMER, current sensing (Deutz F4L1011-powered units only)
. . . 31 . . . . . . . . . . . . . 190 861 . . LABEL, warning electric shock and moving parts . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . 200 910 . . LABEL, warning, electric shock and moving parts (CE models only) . . . .
OM-496 Page 78
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
3
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-5. Panel, Front w/Components – CC/CV Models (Continued)
. . . 31 . . . . . . . . . . . . ♦197 399
. . . 32 . . . . . . . . . . . . . 193 260
. . . 33 . . . . . . . . . . . . . 193 258
. . . 34 . . . . . . . . . . . . . 190 323
. . . 35 . . . . . S12 . . ♦195 825
. . . 36 . . . . . . . . . . . . . 201 125
. . . 37 . . PC4, PC5 . 189 744
. . . 38 . . . . . . . . . . . . . 039 046
. . . . . . . . . . . . . . . . . . . 180 735
. . . 39 . . . . . . . . . . . . . 134 201
. . . 40 . . . . . . . . . . . . . 181 169
. . . 41 . . . . . . . . . . . . . 186 621
. . . 42 . . . . . . . . . . . . ♦059 773
. . . 43 . . . . . . . . . . . . ♦010 647
. . . 44 . . . . . . . . . . . . . 039 047
. . . 45 . . . . . . . . . . . . ♦196 073
. . . 46 . . . . . . . . . . . . . 193 143
. . . 47 . . . . . . . . . . . . . 021 385
. . . 48 . . . . . . . . . . . . . . 119 014
. . . 49 . . . . . . . . . . . . . 170 391
. . . 50 . . . . . PL1 . . . 191 241
. . . 51 . . . . FUEL . . . 191 242
. . . 52 . . . . . HM . . . . . 118 058
. . . 53 . . . . . . . . . . . . . 097 922
. . . 54 . . . . . . . . . . . . . 189 161
. . . 55 . . . . . . . . . . . . . 010 647
. . . 56 . . . . . . . . . . . . . 097 924
. . . 57 . . . . . . . . . . . . . 202 209
. . . . . . . . . . . . . . . . . . . 193 158
. . . . . . . . . . PLG6 . . . 136 810
. . . . . . . . . . PLG8 . . . 193 184
. . . . . . . . . PLG13 . . 148 439
. . . . . . . . . . PLG3 . . . 166 680
. . . . . . . . . . . . . . . . . . . 088 731
. . . . . . . . . . . . . . . . . . . 135 873
. . . . . . . . . . . . . . . . . . . 187 654
. . . . . . . . . . . . . . . . . . . 024 103
+
. . LABEL, warning 3 ph auxiliary power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, receptacle 2.250 dia lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, receptacle GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSEMBLY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOOT, magnetic shutdown switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONN, circ ms protective cap size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LED, red 12V 4 ind lights panel mtg round . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GAUGE, fuel elec switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, pointer .875 dia x .250 ID w/set screws plstc . . . . . . . . . . . . . . . . .
. . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc . . . . . . . . . . . . . . . . .
. . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HARNESS, unit weld control – CV (consisting of) . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, (kit) rect univ 084 4p/s 1 row plug cable lkg . . . . . . . . . .
. . . . CONNECTOR, rect cinch 30 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, (kit) rect univ 039 10p/s 2 row plug cable . . . . . . . . . . . .
. . . . CONNECTOR, (kit) rect univ 084 12p/s 3 row plug cable . . . . . . . . . . . .
. . . . BUSHING, snap-in nyl .375 ID x .500 mtg hole . . . . . . . . . . . . . . . . . . . .
. . . . CLIP, conduit convoluted 1/2 in mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SEAL, wire univ 12p/s 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLANK, snap-in nyl .750 mtg hole blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
1
1
2
1
2
12
2
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 192 505 or Label Kit 201 061 (CE models only).
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-496 Page 79
Hardware is common and
18
not available unless listed.
15
16
17
11
14
10
12
19
20
21
13
9
22
23
8
7
6
5
3
2
1
4
25
27
28
29
16
24
26
30
31
32
33
34
28
802 552
Figure 12-6. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-6. Generator (Figure 12-1 Item 100)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
6
7
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
. . . . . . . . . . . . . 132 053
. . . . . . . . . . . . . 183 387
. . . . . . . . . . . . . . 195 911
. . . . . . . . . . . . . 143 220
. . . . . . . . . . . . . 190 464
. . . . . . . . . . . . +191 478
. . . . . . . . . . . +♦197 334
. . . . . . . . . . . . . 013 367
. . . . . . . . . . . . . 176 106
. . . . . . . . . . . . . 190 197
. . . . . . . . . . . . . 172 674
. . . . . . . . . . . . . 039 207
. . . . . . . . . . . . . 198 627
. . . . . . . . . . . . . 024 617
. . . . . . . . . . . . . 053 390
. . . . . . . . . . . . . 195 547
. . . . . . . . . . . . . 049 026
. . . . . . . . . . . . . 083 883
. . . . . . . . . . . . . 202 301
. . . . . . . . . . . . . 197 487
. . . . . . . . . . . . . 197 486
. . . . . . . . . . . . . 605 231
. . . . . . . . . . . . . 194 512
. . . . . . . . . . . . . 183 387
OM-496 Page 80
. . SCREW, .375–16x1.50 hex hd–pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, conical spring .406 ID x .875 OD pltd . . . . . . . . . . . . . . . . . . . . .
. . ENDBELL, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, exciter/aux pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, weld assembly complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, weld assembly complete (full kVA option) . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts (CE models only) . . . . . . . . . . . . . . . . . . . . .
. . GUARD, generator wire mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPRING, ext .240 OD x .041 wire x 3.500pld . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROTOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RING, rtng ext 1.375 shaft x .050thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BEARING, ball rdl sgl row 1.370 x 2.830 x .6 . . . . . . . . . . . . . . . . . . . . . .
. . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, M10-1.5 x 25hexhd pln 8.8pln . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, lock .402 ID x 0.709 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PLATE, flex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FLYWHEEL, engine Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ADAPTER, engine Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, m10–1.5x 35 hex hd–pln 8.8 pld . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat 1.250 od x .406id x 7ga thk stl pld . . . . . . . . . . . . . . . . . . . .
. . WASHER, cone .380idx .860odx.109t stl pld 4000lbs . . . . . . . . . . . . . . . .
6
6
1
1
1
1
1
2
2
1
2
1
1
1
1
1
6
10
1
1
1
4
4
6
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-6. Generator (Continued)
. . . 23 . . . . . . . . . . . . . 198 631
. . . 24 . . . . . . . . . . . . . 191 579
. . . . . . . . . . . . . . . . . . . 195 560
. . . 25 . . . . . . . . . . . . . 172 555
. . . 26 . . . . . . . . . . . . . 602 159
. . . 27 . . . . . . . . . . . . . 601 961
. . . 28 . . . . . . . . . . . . . . 602 211
. . . 29 . . . . . . . . . . . . . 139 341
. . . 30 . . . . . . . . . . . . . *190 823
. . . 31 . . . . . . . . . . . . . 188 560
. . . 32 . . . . . . . . . . . . . 189 142
. . . 33 . . . . . . . . . . . . . 602 242
. . . 34 . . . . . . . . . . . . . 604 534
. . . . . . . . . . . . . . . . . . . 190 259
. . . . . . . . . . PLG1 . . . 168 071
. . . . . . . . . . . . . . . . . . . 187 651
. . NUT, m10 hex lock nut stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, starter hole Perkins/Continental . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUARD, starter hole deutz 912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, M10-1.5 x 50hexhd pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, .312–18x .75 hexwhd.66d stl pld slffmg tap–rw . . . . . . . . . . . . .
. . SCREW, .312-18 x 2.25hexhd pln gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, lock .318 ID x 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRUSHHOLDER ASSEMBLY, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat .375IDx0.875odx.083t stl pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, .312–18x1.25 hex hd–pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . HARNESS, brush (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg . . . . . . . . .
. . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1
1
6
6
4
6
4
3
3
1
2
2
1
1
1
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 190 469 or Label Kit 201 061 (CE models only).
*Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-496 Page 81
Hardware is common and
4
not available unless listed.
3
2
1
5
6
7
8
9
802 279-A
Figure 12-7. Main Rectifier Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-7. Main Rectifier Assembly (Figure 12-1 Item 121)
...................
... 1 .............
... 2 .............
... 3 .............
... 4 .............
. . . 5 . . . . PC3 . . .
... 6 .............
... 7 .............
. . . 8 . D3, D5, D7
. . . 9 . D2, D4, D6
188 134
188 137
188 517
188 135
134 201
201 449
188 136
188 493
037 956
037 957
. . RECTIFIER (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTION BOARD, rectifier AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUS BAR, connection board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ENCLOSURE, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSEMBLY, protection . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . INSULATOR, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HEAT SINK, rectifier al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
3
2
3
1
8
2
3
3
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-496 Page 82
Effective January 1, 2000
(Equipment with a serial number preface of “LA” 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
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
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 185 & Spoolmate 250
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.
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 7/00
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 for:
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
 2001 Miller Electric Mfg. Co.
1/01