Miller Electric | OM-494 | Owner`s manual | Miller Electric OM-494 Owner`s manual

Miller Electric OM-494 Owner`s manual
OM-494
191 862P
January 2005
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Dual-Operator Engine Driven Welding
Generator
Miller DU-OP

Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
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.
Mil_Thank 7/03
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. AC Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Activating The Dry Charge Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Safety Information For Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . .
5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . .
5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . .
5-14. Making Single Operator CC Weld Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16. Installing Ether Cylinder (Optional Ether Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18. Remote 14 Receptacle Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Weld Controls (See Section 6-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Weld Control Descriptions (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. 120 Volt And 240 Volt Duplex Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Servicing Optional Ether Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Checking And Replacing Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Resetting Fan Belt Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
32
32
34
35
36
37
37
38
39
40
41
42
46
48
48
49
50
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_8/03
Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Use only well-maintained equipment. Repair or replace damaged parts at
once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Only qualified persons should install, operate, maintain, and repair this unit.
Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
During operation, keep everybody, especially children, away.
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.
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 1-7. Read and follow all Safety Standards.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all metal
parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats or covers
big enough to prevent any physical contact with the work or ground.
Do not use AC output in damp areas, if movement is confined, or if there is a
danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on unit.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing
wet clothing; on metal structures such as floors, gratings, or scaffolds;
when in cramped positions such as sitting, kneeling, or lying; or when there
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most
situations, use of a DC, constant voltage wire welder is recommended.
And, do not work alone!
Disconnect input power or stop engine before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
Properly install and ground this equipment according to its Owner’s Manual
and national, state, and local codes.
Always verify the supply ground — check and be sure that input power cord
ground wire is properly connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded receptacle outlet.
When making input connections, attach proper grounding conductor first −
double-check connections.
Frequently inspect input power cord for damage or bare wiring — replace
cord immediately if damaged — bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly with a separate cable.
Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.
SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine.
Stop engine on inverter and discharge input capacitors according to
instructions in Maintenance Section before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove welding
fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instructions for metals, consumables, coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while wearing an airsupplied respirator. Always have a trained watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury
or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and
irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated
steel, unless the coating is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an air-supplied respirator. The
coatings and any metals containing these elements can give off toxic fumes
if welded.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved
air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible
and invisible (ultraviolet and infrared) rays that can burn eyes
and skin. Sparks fly off from the weld.
Wear a welding helmet fitted with a proper shade of filter to protect your face
and eyes from arc rays and sparks when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from flash and glare;
warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (wool
and leather) and foot protection.
OM-494 Page 1
WELDING can cause fire or explosion.
HOT PARTS can cause severe burns.
Welding on closed containers, such as tanks, drums, or
pipes, can cause them to blow up. Sparks can fly off from the
welding arc. The flying sparks, hot workpiece, and hot
equipment can cause fires and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or fire. Check and be sure
the area is safe before doing any welding.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not
possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause
fire on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes, unless
they are properly prepared according to AWS F4.1 (see Safety Standards).
Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and
causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at contact tip
when not in use.
Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches, from your
person before doing any welding.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
work and have a fire watcher and extinguisher nearby.
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.
Allow cooling period before maintaining.
Wear protective gloves and clothing when working on
a hot engine.
Do not touch hot engine parts or just-welded parts
bare-handed.
NOISE can damage hearing.
Noise from some processes or equipment can damage
hearing.
Wear approved ear protection if noise level is high.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding operations.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
normally part of the welding process, be sure to treat them
carefully.
Protect compressed gas cylinders from excessive heat, mechanical
shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary support or
cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in
good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in use or
connected for use.
Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
1-3. Engine Hazards
MOVING PARTS can cause injury.
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.
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.
Always keep nozzle in contact with tank when fueling.
OM-494 Page 2
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
Stop engine before installing or connecting unit.
Have only qualified people remove guards or covers for maintenance
and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect negative (−)
battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving parts.
Reinstall panels or guards and close doors when servicing is finished
and before starting engine.
Before working on generator, remove spark plugs or injectors to keep
engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator components.
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is cold to
avoid scalding.
Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise
in maintenance section or engine manual).
If the engine is warm, checking is needed, and there is no overflow tank,
follow the next two statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before completely removing cap.
ENGINE EXHAUST GASES can kill.
Use equipment outside in open, well-ventilated areas.
If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from flammables.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in required areas — see applicable codes.
1-4. Compressed Air Hazards
BREATHING COMPRESSED AIR can
cause serious injury or death.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
COMPRESSED AIR can cause injury.
Wear approved safety goggles.
Do not direct air stream toward self or others.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
Release air pressure from tools and system before
servicing, adding or changing attachments, or opening compressor oil drain or oil fill cap.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
Do not touch hot compressor or air system parts.
Let system cool down before touching or servicing.
READ INSTRUCTIONS.
Read Owner’s Manual before using or servicing unit.
Stop engine and release air pressure before
servicing.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running gear, gas
cylinders, trailer, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or stopping engine.
Do not let low voltage and frequency caused by low
engine speed damage electric motors.
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.
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.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where
applicable.
FLYING SPARKS can cause injury.
OVERUSE can cause OVERHEATING.
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.
Sparks can cause fires — keep flammables away.
OM-494 Page 3
READ INSTRUCTIONS.
Use only genuine MILLER/Hobart replacement
parts.
Perform engine and air compressor (if applicable)
maintenance and service according to this manual
and the engine/air compressor (if applicable) manuals.
H.F. RADIATION can cause interference.
ARC WELDING 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.
Electromagnetic energy can interfere with sensitive
electronic equipment such as microprocessors,
computers, and computer-driven equipment such as
robots.
Be sure all equipment in the welding area is electromagnetically compatible.
To reduce possible interference, keep weld cables as short as possible,
close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic
equipment.
Be sure this welding machine is installed and grounded according to this
manual.
If interference still occurs, the user must take extra measures such as
moving the welding machine, using shielded cables, using line filters, or
shielding the work area.
1-6. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1-7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www.
sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
in Toronto 416-747-4044, website: www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices—phone for Region 5, Chicago, is
312-353-2220, website: www.osha.gov).
1-8. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
OM-494 Page 4
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 8/03
Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.
2-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés par
des symboles adjacents aux directives.
Identifie un message de sécurité particulier.
Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles 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.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité énumérées à la section 2-6 . Veuillez lire et respecter toutes
ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
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.
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.
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.
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.
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.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
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.
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.
Des précautions de sécurité supplémentaires sont requises dans des envi-
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.
ronnements à risque comme: les endroits humides ou lorsque l’on porte
des vêtements mouillés; sur des structures métalliques au sol, grillages et
échafaudages; dans des positions assises, à genoux et allongées; ou
quand il y a un risque important de contact accidentel avec la pièce ou le
sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence:
1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un
poste à souder manuel (électrode enrobée) DC, 3) un poste à souder manuel AC avec tension à vide réduite. Dans la plupart des cas, un poste
courant continu de type CV est recommandé. Et, ne pas travailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation,
à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre
du sectionneur ou que la fiche du cordon est raccordée à une prise
correctement mise à la terre.
OM-494 Page 5
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B
pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
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.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
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.
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.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
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.
LE SOUDAGE peut provoquer un incendie ou une explosion.
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
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.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
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.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
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.
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.
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.
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.
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.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords convenables pour cette application spécifique; les maintenir ainsi
que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
les équipements associés et les publication P-1 CGA énumérées dans les
normes de sécurité.
2-3. Dangers existant en relation avec le moteur
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
OM-494 Page 6
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
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.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Toujours vérifier le niveau de liquide de refroidissement dans le vase d’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.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
DES ORGANES MOBILES peuvent
provoquer des blessures.
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.
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.
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.
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.
Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé −
voir codes en vigueur.
2-4. Dangers liés à l’air comprimé
RESPIRER L’AIR COMPRIMÉ peut provoquer des blessures graves ou causer
la mort.
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un incendie ou une explosion.
Ne pas utiliser l’air comprimé pour respirer.
Utiliser l’air comprimé seulement pour le coupage, gougeage et les outils pneumatiques.
Ne pas couper ou gouger à proximité de produits
inflammables.
Surveillez et garder un extincteur à proximité.
L’AIR COMPRIMÉ peut provoquer
des blessures.
DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.
Porter des lunettes de sécurité approuvées.
Ne pas diriger le jet d’air vers d’autres ou soi−
même.
Ne pas toucher le compresseur ou d’autres éléments du circuit air comprimé chauds.
Laisser l’ensemble se refroidir avant de toucher
ou d’effectuer la maintenance.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provoquer des blessures.
LIRE LES INSTRUCTIONS.
Relâcher la pression d’air de l’outillage ou du système avant d’effectuer la maintenance, avant de
changer ou de rajouter des éléments ou avant
d’ouvrir la purge ou le bouchon de remplissage
d’huile.
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
Arrêter le moteur et relâcher la pression avant
d’effectuer la maintenance.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la
maintenance
LA CHUTE DE L’APPAREIL peut
blesser.
Utiliser l’anneau de levage uniquement pour soulever
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.
Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
OM-494 Page 7
LE SURCHAUFFEMENT peut endommager le moteur électrique.
LIRE LES INSTRUCTIONS.
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.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
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.
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
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.
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.
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.
Utiliser seulement les pièces de rechange d’origine.
Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du
moteur/compresseur (si applicable).
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement 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.
2-6. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping, norme American Welding Society AWS F4.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101
(téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de
la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web :
www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard Rexdale,
Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site
Web : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,
norme NFPA 51B, de la National Fire Protection Association, P.O. Box
9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
770−3000, site Web : www.nfpa.org et www.sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
Web : www.osha.gov).
2-7. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques
basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent préoccupants.
Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité de spécialistes du
National Research Council a conclu : « L’accumulation de preuves n’a pas
démontré que l’exposition aux champs magnétiques et aux champs électriques à haute fréquence constitue un risque pour la santé humaine ».
Toutefois, les études et l’examen des preuves se poursuivent. En attendant
les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs électromagnétiques pendant le soudage ou le
coupage.
OM-494 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
SECTION 3 − DEFINITIONS
3-1. Symbols And Definitions
A
Stop Engine
Start Engine
Ether Starting Aid
Engine
Do Not Switch
While Welding
Or Under Load
Battery (Engine)
Circuit Breaker
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
Panel/Local
Remote
On
Temperature
Output (Contactor)
Alternating
Current
Stick (SMAW)
Welding
TIG (GTAW)
Welding
MIG (GMAW)
Welding
3
Three Phase
Seconds
1
Single Phase
Amperes
Time
V
h
Hours
s
Read Operator’s
Manual
OM-494 Page 9
SECTION 4 − SPECIFICATIONS
4-1. Description
This unit has two CC/CV modules with separate weld controls for applications where two welding arcs are needed. A
Welder Selector switch controls whether one or both sets of weld output terminals are active (see Section 6-2). When
the unit is operated in the dual operator mode, each welder has CC and CV weld output available for Stick, TIG, and
MIG welding. When in the single operator mode, CC weld output is available to the welder on the Welder B (right) side
only (CV not active in single operator mode).
4-2. Weld, Power, And Engine Specifications
Weld
Mode
Weld
Stations
Available
Weld
Output
Weld
Output
Range
Max.
OpenCircuit
Voltage
Rated
Welding
Output
Single
1
(Right Side)
CC/DC
30 − 600 A
85
550 A at 30
Volts DC, 40%
Duty Cycle
CC/DC
15 − 300 A
85
CV/DC
10 − 32 V
49
Dual
2
(Both Sides)
Generator Power
Rating
Single-Phase,
4 kVA/kW, 34/17 A,
120/240 V AC,
50/60 Hz
275 A at 31
Volts DC, 40%
Duty Cycle
(4
( kVA/kW
/
Shared By
y
All Receptacles)
R
t l )
Engine
Fuel
Capacity
Deutz F3L-912
Air-Cooled,
Air
Cooled,
Th
Three-Cylinder,
C li d
41.5 HP Diesel
Engine
22.3 gal
(84.4 L)
4-3. Dimensions, Weights, And Operating Angles
Dimensions
Height
47-5/8 in (1210 mm)
Width
31-1/4 in (794 mm)
Depth
60-1/2 in (1537 mm)
A
59-1/8 in (1502 mm)
B
47-1/4 in (1200 mm)
C
43-1/4 in (1099 mm)
D
32-3/4 in (832 mm)
E
24-15/16 in (633 mm)
F
10-1/2 in (267 mm)
G
6-1/2 in (165 mm)
H
2-7/8 in (73 mm)
J
29-7/8 in (759 mm)
K
11/16 in (24 mm)
L
21/32 in (17 mm) Dia.
16 Holes
Weight
2005 lb (909 kg)
OM-494 Page 10
L
Do not exceed tilt angles or engine could
be damaged or unit could tip.
Engine End
Do not move or operate
p
unit where it could
tip
tip.
A
C
D
B
E
17 5°
17.5
F
K
J
H
20°
G
17.5°
20°
angles_1 8/99
158 699
4-4. Fuel Consumption
The curve shows typical fuel use under the combined weld loads of both
sides (Welder A and Welder B).
7.57
1.70
2.00
6.62
1.46
1.75
5.67
1.25
1.50
4.73
1.04
1.25
3.78
0.83
1.00
2.84
0.62
0.75
1.98
0.40
0.50
0.95
0.21
0.25
CV
0
50
100 150 200 250 300 350 400 450 500 550 600
DC WELD AMPERES AT 40% DUTY CYCLE
U.S. GAL./HR.
IMP. GAL./HR.
LITERS/HR.
0
CC
195 711
4-5. AC Generator Power
The ac power curve shows the generator 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
5
10
15
20
AC AMPERES IN 240V MODE
25
30
0
10
20
30
40
AC AMPERES IN 120V MODE
50
60
193 018
OM-494 Page 11
4-6. Duty Cycle And Overheating
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.
Dual Operator Mode − 40% Duty Cycle At 275 Amperes From Each Side
Single Operator Mode − 40% Duty Cycle At 550 Amperes From Welder B side (Right)
If a weld module overheats, the
High Temperature light goes on and
the thermostat opens to stop weld
output to that module. Wait fifteen
minutes for module to cool. Reduce
amperage, voltage, or duty cycle
before welding.
4 Minutes Welding
6 Minutes Resting
This unit has separate duty cycle
ratings for each operating mode. If
the unit is operated in the dual operator mode, the unit is rated at 40%
duty cycle. This means each side of
the unit can be operated at 275 amperes at 40% duty cycle.
When the unit is operated in the
single operator mode, the Welder B
side (right) is rated at 40% duty
cycle (550 A at 40% duty cycle).
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
Ref. rduty1 5/95 − 194 313-A
OM-494 Page 12
4-7. Volt-Ampere Curves
A. CC/DC − Single Mode
The volt-ampere curve shows the
minimum, medium, and maximum
voltage and amperage output capabilities of the welding generator.
Curves of all other settings fall between the curves shown.
100
DC VOLTS
80
60
MIN
MED
MAX
40
20
0
0
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
B. CC/DC − Dual Mode
100
DC VOLTS
80
MIN
60
MED
MAX
40
20
0
0
50
100 150 200 250 300 350 400 450 500
DC AMPERES
C. CV/DC Mode
100
DC VOLTS
80
60
40
MAX
MED
20
0
MIN
0
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
194 397 / 194 398 / 194 399
OM-494 Page 13
SECTION 5 − INSTALLATION
NOTE
When facing the front panel, the Welder B controls and weld terminals are on the
right and the Welder A controls and weld terminals are on the left.
5-1. Installing Welding Generator
Movement
Airflow Clearance
Location
18 in
(460 mm)
Do Not Lift Unit From End
18 in
(460 mm)
18 in
(460 mm)
OR
OR
18 in
(460 mm)
18 in
(460 mm)
Grounding
1
GND/PE
Always securely fasten welding
generator onto transport vehicle
or trailer and comply with all DOT
and other applicable codes.
2
Always ground generator frame
to vehicle frame to prevent electric shock and static electricity
hazards.
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Electrically bond generator frame to
vehicle frame by metal-to-metal
contact.
Bed liners, shipping skids, and some running
gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding terminal to bare metal on the vehicle frame as shown.
1
3
2
3
Equipment Grounding Terminal
(On Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Connect cable from equipment ground
terminal to metal vehicle frame. Use #10
AWG or larger insulated copper wire.
Be sure equipment connected to
the 240 V receptacles is GFCIprotected.
install1 11/02* − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-494 Page 14
5-2. Activating The Dry Charge Battery
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
OR
+
−
30 A For 12 Minutes
Tools Needed:
drybatt1 2/96 − S-0886
OM-494 Page 15
5-3. Connecting The Battery
Connect (−) Cable Last.
+
−
190 377
5-4. Installing Exhaust Pipe
Stop engine and let cool.
Do not blow exhaust toward
air cleaner or air intake.
Top View
Tools Needed:
1/2 in
OM-494 Page 16
exh_pipe2 4/96 − 154 089-A / 154 611 / 190 377
5-5. Engine Prestart Checks
Check all fluids daily. Engine must
be cold and on a level surface.
Follow run-in procedure in engine
manual. If unburned fuel and oil collect in exhaust pipe during run-in,
see Section 10.
1/2 in
(13 mm)
Fuel
Full
Do not use gasoline. Gasoline will damage engine.
Add diesel fuel before starting
engine the first time (see maintenance label for specifications). Fill
fuel tank up to 1/2 in. (13 mm) from
top to allow room for expansion.
Open fuel shut-off valve.
Diesel
Do not run out of fuel or air enters
fuel system and causes starting
problems. See engine manual to
bleed air from fuel system.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see maintenance label).
Engine stops if oil pressure is
too low.
To
improve
starting:
Valve Open
cold
weather
I
Keep battery in good condition.
Store battery in warm area.
O
Use fuel formulated for cold
weather (diesel fuel can gel in
cold weather). Contact local
fuel supplier for fuel information.
Full
Use correct grade oil for cold
weather.
Ref. 158 633-C / S-176 697
Notes
Start Your Professional
Welding Career Now!
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
Over 80,000 trained
since 1930!
OM-494 Page 17
5-6. Safety Information For Connecting To Weld Output Terminals
UNEXPECTED WELD OUTPUT can cause injury or fire.
Both weld outputs can be live (ON) when Welder Selector switch is in Welder A/Welder B position and engine is running.
Disconnect or insulate any unused cables.
Know where cables are located BEFORE starting engine.
ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical connections.
Stop engine before making any weld output connections.
Do not connect welding output of different polarities to the same structure.
See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual).
When welding on the same workpiece, all connections to the workpiece must be of the same polarity.
Do not handle or come in contact with two live electrodes at the same time.
ELECTRIC SHOCK can kill; TWO TIMES NORMAL OPEN-CIRCUIT VOLTS can exist between electrode holders of opposite polarity.
Do not touch electrode holders of opposite polarity at the same time.
Separate electrode holders of opposite polarity to prevent contact.
Consult ANSI Z49.1 for common grounding safe practices.
5-7. Weld Output Terminals
Welder B (Right) Side
Welder A (Left) Side
3
2
1
1
2
3
Dinse receptacles only on units
with Polarity switch option.
Tools Needed:
4
3/4 in
Ref. 190 377 / 802 292-A / 802 554
Stop engine.
4
Dinse Weld Receptacles (Only On
Units With Polarity Switch Option)
1
Negative (−) Weld Output Terminal
2
CV Weld Output Terminal
See Sections 5-8 thru 5-13 for dual operator
output connections for CC and CV welding.
3
CC Weld Output Terminal
See Section 5-14 for single operator output
OM-494 Page 18
connections (CC only).
If unit has the Polarity switch option, the
Negative (−) weld output terminals are labeled Work receptacles and the CC weld
output terminals are labeled Electrode receptacles.
5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables
Tools Needed:
3/4 in
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B (Right) Side
Welder A (Left) Side
Note position
of Process
Selector
switches.
2
1
2
3
Ref. 190 377 / 802 292-A
Stop engine.
Do not exceed machine duty cycle.
Use Dual Operator mode for CC and
CV welding (see Section 6-1).
See Section 5-15 for proper cable size.
1 Strain Reliefs
Route cables through strain reliefs.
2 Electrode Holder Cables
3 Work Cables
For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect work
cables to Negative (−) terminals and electrode holder cables to CC terminals.
For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cables to
CC terminals and electrode holder cables
to Negative (−) terminals.
If unit has the Polarity switch option, connect work cables to Work receptacles and
electrode holder cables to Electrode receptacles.
Be sure Process Selector switches are
set correctly. See Section 6-3.
OM-494 Page 19
5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable
Tools Needed:
3/4 in
INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.
When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−) weld terminals, and connect a single weld cable of adequate size from the Welder B (right) Negative (−) terminal to the workpiece.
When using these connections as a common work terminal, all connections must be of the same polarity.
For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see Section 5-15
for proper cable size).
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B (Right) Side
Welder A (Left) Side
Note position
of Process
Selector
switches.
1
4
2
2
3
Ref. 190 377 / 802 292-A
Stop engine.
Do not exceed machine duty cycle.
For common
work connection, work
cable must be able to carry combined
weld output of both CC weld output terminals (see Section 5-15 for proper
cable size).
Use Dual Operator mode for CC and
CV welding (see Section 6-1).
1 Strain Relief
Route cables through strain reliefs.
2 Electrode Holder Cables
3 Work Jumper Cable
OM-494 Page 20
4
Common Work Cable
For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect common
work cable and work jumper cable to Welder B (right) Negative (−) terminal. Connect
other end of work jumper cable to Welder A
(left) Negative (−) terminal.
Connect electrode holder cables to CC terminals.
For Stick/TIG Direct Current Electrode
Negative (DCEN), connect common work
cable and work jumper cable to Welder B
(right) CC terminal. Connect other end of
work jumper cable to Welder A (left) CC terminal.
Connect electrode holder cables to Negative (−) terminals.
If unit has the Polarity switch option, connect common work cable and work jumper
cable to Welder B (right) Work receptacle.
Connect other end of work jumper cable to
Welder A (left) Work receptacle.
Connect electrode holder cables to Electrode receptacles.
Be
sure Process Selector switches
and optional Polarity switches are set
correctly. See Section 6-3.
5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables
Tools Needed:
3/4 in
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B (Right) Side
Welder A (Left) Side
Note position
of Process
Selector
switches.
2
Note position
of optional Polarity switch.
Note position
of optional
Polarity
switch.
2
1
3
Ref. 190 377 / 802 292-A
Stop engine.
Do not exceed machine duty cycle.
Use Dual Operator mode for CC and
CV welding (see Section 6-1).
See Section 5-15 for proper cable size.
1
Strain Reliefs
Route cables through strain reliefs.
2
Wire Feeder Cables
3
Work Cables
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect work
cables to Negative (−) terminals and wire
feeder cables to CV terminals.
For MIG and FCAW Direct Current Electrode Negative (DCEN), connect work
cables to CV terminals and wire feeder
cables to Negative (−) terminals.
If unit has the Polarity switch option, connect work cables to Work receptacles and
wire feeder cables to CV receptacles.
Place optional Polarity switches in Re-
verse position when using CV weld receptacles. There is no CV weld output
when switch is in Straight position.
Be sure Process Selector and Polarity
switches are set correctly. See Section
6-3.
OM-494 Page 21
5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable
Tools Needed:
3/4 in
INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.
When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−) weld terminals, and connect a single weld cable of adequate size from the Welder B (right) Negative (−) terminal to the workpiece.
When using these connections as a common work terminal, all connections must be of the same polarity.
For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see Section 5-15
for proper cable size).
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B (Right) Side
Welder A (Left) Side
Note position
of Process
Selector
switches.
1
Note position
of optional
Polarity
switch.
4
2
3
Note position of optional
Polarity switch.
2
Ref. 190 377 / 802 292-A
Stop engine.
Do not exceed machine duty cycle.
For common
work connection, work
cable must be able to carry combined
weld output of both CC weld output terminals (see Section 5-15 for proper
cable size).
4
Common Work Cable
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect common work cable and work jumper cable to
Welder B (right) Negative (−) terminal. Connect other end of work jumper cable to
Welder A (left) Negative (−) terminal.
Use Dual Operator mode for CC and
Connect wire feeder cables to CV terminals.
1
For MIG and FCAW Direct Current Electrode Negative (DCEN), connect common
work cable and work jumper cable to Welder B (right) CV terminal. Connect other end
of work jumper cable to Welder A (left) CV
terminal.
CV welding (see Section 6-1).
Strain Relief
Route cables through strain reliefs.
2
Wire Feeder Cables
3
Work Jumper Cable
OM-494 Page 22
Connect wire feeder cables to Negative (−)
terminals.
If unit has the Polarity switch option, connect common work cable and work jumper
cable to Welder B (right) Work receptacle.
Connect other end of work jumper cable to
Welder A (left) Work receptacle.
Connect wire feeder cables to CV receptacles.
Place optional Polarity switches in Re-
verse position when using CV weld receptacles. There is no CV weld output
when switch is in Straight position.
Be sure Process Selector and Polarity
switches are set correctly. See Section
6-3.
5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables
Tools Needed:
3/4 in
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B (Right) Side
Welder A (Left) Side
Note position
of Process
Selector
switches.
3
Note position
of optional
Polarity
switch.
1
2
4
Stop engine.
Do not exceed machine duty cycle.
Use Dual Operator mode for CC and
CV welding (see Section 6-1).
See Section 5-15 for proper cable size.
1
Strain Reliefs
Route cables through strain reliefs.
2
Electrode Holder Cable
3
Wire Feeder Cable
4
Work Cables
For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect work cable
to Negative (−) terminal and electrode holder cable to CC terminal.
For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cable to
CC terminal and electrode holder cable to
Negative (−) terminal.
Be sure Process Selector switches are
set correctly. See Section 6-3.
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect work
cable to Negative (−) terminal and wire
feeder cable to CV terminal.
For MIG and FCAW Direct Current Electrode Negative (DCEN), connect work
cable to CV terminal and wire feeder cable
to Negative (−) terminal.
Ref. 190 377 / 802 292-A
For Stick/TIG welding on units with Polarity
switch option, connect work cable to Work
receptacle and electrode cable to Electrode
receptacle.
For MIG/FCAW welding on units with Polarity switch option, connect work cable to
Work receptacle and wire feeder cable to
CV receptacle.
Place optional Polarity switches in Re-
verse position when using CV weld receptacles. There is no CV weld output
when switch is in Straight position.
Be sure Process Selector and Polarity
switches are set correctly. See Section
6-3.
OM-494 Page 23
5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable
Tools Needed:
3/4 in
INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.
When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−) weld terminals, and connect a single weld cable of adequate size from the Welder B (right) Negative (−) terminal to the workpiece.
When using these connections as a common work terminal, all connections must be of the same polarity.
For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see Section 5-15
for proper cable size).
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B (Right) Side
Welder A (Left) Side
Note position
of Process
Selector
switches.
1
Note position of
optional Polarity
switch.
5
2
3
4
Ref. 190 377 / 802 292-A
Stop engine.
Do not exceed machine duty cycle.
For
common work connection, work
cable must be able to carry combined
weld output of both CC weld output terminals (see Section 5-15 for proper
cable size).
Use Dual Operator mode for CC and CV
welding (see Section 6-1).
1
Strain Reliefs
Route cables through strain reliefs.
2
Electrode Holder Cable
3
Wire Feeder Cable
4
Work Jumper Cable
5
Common Work Cable
OM-494 Page 24
For Direct Current Electrode Positive
(DCEP), connect common work cable and
work jumper cable to Welder B (right) Negative (−) terminal. Connect other end of work
jumper cable to Welder A (left) Negative (−)
terminal.
Connect electrode holder cable to either CC
terminal.
Connect wire feeder cable to CV terminal on
other side.
Be sure Process Selector switches are
set correctly. See Section 6-3.
For Direct Current Electrode Negative
(DCEN), connect common work cable and
work jumper cable to Welder B (right) CC
terminal. Connect other end of work jumper
cable to Welder A (left) CV terminal.
Connect electrode holder cable to either
Negative (−) terminal, and wire feeder cable
to remaining Negative (−) terminal.
If unit has the Polarity switch option, connect
common work cable and work jumper cable
to Welder B (right) Work receptacle. Connect other end of work jumper cable to Welder A (left) Work receptacle.
Connect electrode holder cable to either
Electrode receptacle.
Connect wire feeder cable to CV receptacle
on other side.
Place optional
Polarity switch in Reverse position when using CV weld receptacle. There is no CV weld output
when switch is in Straight position.
Be sure Process Selector and Polarity
switches are set correctly. See Section
6-3.
5-14. Making Single Operator CC Weld Connections
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B(Right) Side
Welder A (left) Terminals Inactive
In Single Operator Mode
Note position
of Process
Selector
switch.
1
3
2
Tools Needed:
190 377 / 802 292-A
3/4 in
Stop engine.
Do not exceed machine duty cycle.
Welder A (left) weld output terminals
are disabled in Single Operator mode.
Connect only to Welder B (right) terminals for Single Operator mode operation.
Use Single Operator mode for CC welding only. Welder A and Welder B CV
weld output terminals are disabled in
Single Operator mode. (see Section
5-8).
See Section 5-15 for proper cable size.
See Section 5-15 for proper cable size.
1 Strain Relief
Route cables through strain reliefs.
2 Electrode Holder Cable
3 Work Cable
For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect work cable
to Negative (−) terminal and electrode holder cable to CC terminal.
For Stick/TIG Direct Current Electrode Negative (DCEN), connect work cable to CC
terminal and electrode holder cable to Negative (−) receptacle.
If unit has the Polarity switch option, connect work cable to Work terminal and electrode holder cable to Electrode receptacle.
Be sure Process Selector switch is set
correctly. See Section 6-3.
OM-494 Page 25
5-15. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Turn off power before
connecting to weld output terminals.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
600
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
700
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
800
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
4 ea. 4/0
(4x120)
Do not use worn, damaged, undersized, or
poorly spliced cables.
* This
10 − 100% Duty Cycle
chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
OM-494 Page 26
S-0007-F
5-16. Installing Ether Cylinder (Optional Ether Starting Aid)
Stop engine.
Improper handling or exposure to ether can harm your
health. Follow manufacturer’s safety instructions on
cylinder.
1
Do not use Ether Starting Aid
while engine is running.
Open right side door.
1
Ether Cylinder
2
Nozzle
Remove cover and clean cylinder
nozzle.
2
3
3
Clamp
4
Fitting
5
Cap
6
Valve
Remove cap and clean fitting.
Install cylinder on fitting. Tighten
clamp.
4
5
After installing cylinder, wait at
least 10 minutes before using
to let ether particles settle and
prevent atomizer plugging.
6
Put cap on fitting when cylinder is
removed.
ether1 7/96 − 153 382-A / 190 377 / 802 291-A
5-17. Remote 14 Receptacle Information
NOTE
Place Welder Selector switch in Welder A/Welder B position (dual operator mode) for
both remote receptacles to work. Welder A (left) remote receptacle output contactor
and control is disabled when switch is in Welder B position.
Socket*
24 VOLTS AC
Socket Information
A
24 volts ac. Protected by circuit breakers CB5 and CB6.
B
Contact closure to A completes 24 volts ac contactor control circuit.
C
Output to remote control; +10 volts dc in CV, 0 to +10 volts dc in CC.
REMOTE
OUTPUT
CONTROL
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from remote control.
A/V
F
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volts dc per 10 arc volts.
115 VOLTS AC
I
115 volts, 15 amperes, 60 Hz ac. Protected by circuit breakers CB5 and CB6.
J
Contact closure to I completes 115 volts ac contactor control circuit.
K
Chassis common.
G
Circuit common for 24 and 115 volts ac circuits.
GND
*The remaining sockets are not used.
OM-494 Page 27
5-18. Remote 14 Receptacle Connections
Dual Operator Operation
A
B
K
J
I
H
C L N
D M
G
E F
OR
A
B
K
J
I
H
C L N
M
D
G
E F
OR
Single Operator Operation
A
B
K
J
I
H
C L N
D M
G
E F
60
0 AM
PS
OR
Ref. 802 291-A
OM-494 Page 28
SECTION 6 − OPERATING THE WELDING GENERATOR
NOTE
When facing the front panel, the Welder B controls and weld terminals are on the
right and the Welder A side controls and weld terminals are on the left.
6-1. Engine Controls
3
4
1
5
2
190 377
See
Section 6-3 for weld control
descriptions.
1 Engine Start Button
2 Manual Stop Control
3 Ether Starting Aid Switch (Optional)
Push switch up and release while cranking
engine to release ether.
To Start: Press button and use Ether switch
(if necessary). Release button when engine
starts.
If the engine does not start, let engine
come to a complete stop before attempting restart.
To Stop: Pull control out and hold. Release
control when engine stops.
4
Battery Charging Warning Light
Light goes on when battery is not charging.
If light goes on, stop engine and check
engine belt.
5 Engine Hour Meter
OM-494 Page 29
6-2. Weld Controls (See Section 6-3)
1
300 AMPS
300 AMPS
WELDER A
Welder B
600 AMPS
Welder B
60
0 AM
PS
10
2
3
9
4
8
5
7
6
Ref. 191 848
OM-494 Page 30
6-3. Weld Control Descriptions (See Section 6-2)
1 Welder Selector Switch
Use switch to select Dual Operator or Single
Operator welding mode.
Place switch in Welder A/Welder B (dual operator) position for CC and CV output from Welder A (left) and Welder B (right) weld output terminals. Control the weld output from the terminals on each side using the weld controls on
that same side.
Place switch in Welder B (single operator)
position for CC weld output from Welder B
(right) weld output terminals only. CV weld output terminals on both sides do not work when
unit is in Single Operator mode.
Welder A (left) weld output terminals are
disabled in Single Operator mode. Connect only to Welder B (right) terminals for
Single Operator operation.
When in single Operator mode, only CC
weld output is available. Welder A (left)
and Welder B (right) side CV weld output
terminals are disabled in Single Operator
mode. (see Section 5-8).
2 Process Selector Switch
Use switch to select output for weld process.
If switch is in Stick/Tig position, place Welder
Selector switch in Welder A/Welder B or Welder B Position. If switch is in MIG position, place
Welder Selector switch in Welder A/Welder B
position only.
CV weld output for MIG is only available
when Welder Selector switch is in Welder
A/Welder B position. All weld output
stops if either Process Selector switch
is placed in MIG position when Welder
Selector switch is in Welder B position.
3
Arc Force (Dig) Control
Use control to automatically increase amperage as arc length is decreased to assist in arc
starts and reduce the chance of the electrode
sticking in the puddle. Turn clockwise to increase short-circuit amperage. Set at minimum for TIG welding.
4
Hot Start Switch
Use switch to disable hot start circuit. Turn
switch On for Stick (SMAW) and Submerged
Arc (SAW) Welding, and Air Carbon Arc Cutting and Gouging (CAC-A). Turn switch Off for
TIG (GTAW) welding.
When switch is in On position, higher short-circuit amperage helps arc starting. After arc
starts, the front panel or remote Amperage/
Voltage control setting determines weld amperage.
The
hot start circuit does not function
when constant voltage (CV) welding.
5
Amperage/Voltage Control
When Process Selector switch is in the Stick/
TIG position, turn control clockwise to increase amperage. Read amperage from outer
scale of control. The Amperage/Voltage control adjusts amperage only when constant current (CC) welding and does not adjust opencircuit voltage.
When Process Selector switch is in the MIG
position, turn control clockwise to increase
voltage. Voltmeter value changes as control
knob is turned. Control can be adjusted while
welding.
Place optional Polarity switch in Reverse When Welder Selector switch is in Welder
position when using CV weld output.
There is no CV weld output when Polarity
switch is in Straight position.
Do not switch under load or with output on.
B position (single operator mode), weld
amperage is two times the value selected
by the Amperage/Voltage control. For example, if Amperage/Voltage control is set
to 250 A, weld output is actually 500A.
6
Weld Meters
With Process Selector switch in the Stick/Tig
position, meters read 0 (zero) with contactor
off. Meters display actual output voltage and
amperage with contactor on.
With Process Selector switch in the MIG position, voltmeter displays preset voltage with
contactor off. Voltmeter and ammeter display
actual output voltage and amperage with contactor on.
7
High Temperature Shutdown Light
Light goes on and weld output stops if weld
rectifier gets too warm. Let unit cool before
welding.
8
Remote Amperage/Voltage Control
Switch
For front panel control, place switch in Panel
position. For remote control, place switch in
Remote position, and connect remote device
(see Section 5-17).
9
Output (Contactor) Switch
For front panel control of output, place switch
in On (Hot) position. For remote control of output, place switch in Remote position, and connect remote device (see Section 5-17).
Weld output terminals are energized
when Output (Contactor) switch is On
and engine is running.
10 Polarity Switch (Optional)
Do not switch under load.
Use switch to change polarity of weld output
(see Sections 5-7 thru 5-14).
Place optional Polarity switch in Reverse
position when using CV weld receptacle.
There is no CV weld output when switch is
in Straight position.
OM-494 Page 31
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. 120 Volt And 240 Volt Duplex Receptacles
4
6
3
2
5
1
190 376
Be sure equipment connected to the
240 V receptacles is GFCI-protected.
Generator power
is not affected by
position of Welder Selector switch.
4 kVA/kW generator power output is
shared by all receptacles.
1 240 V 20 A AC Receptacle RC1
2 120 V 20 A AC GFCI Receptacle
GFCI 1
3 240 V 20 A AC Receptacle RC2
4 120 V 20 A AC GFCI Receptacle
GFCI 2
Receptacles supply 60 Hz single-phase
power at weld/power speed.
If a ground fault is detected, the GFCI receptacle(s) circuit opens to disconnect the
faulty equipment and the GFCI Reset button pops out. Check for damaged tools,
cords, plugs, etc. connected to the receptacle. Press button to reset receptacle and
resume operation.
At least once a month, run engine at
weld/power speed and press Test button to verify GFCI is working properly.
5 Circuit Breakers CB1 And CB2
6 Circuit Breakers CB3 And CB4
CB1 and CB2 protect RC1 and GFCI 1 from
overload. If CB1 or CB2 opens, RC1 does
not work. 120 volts may still be present at
RC1. If CB2 opens, GFCI 1 does not work.
Press button to reset breaker.
CB3 and CB4 protect RC2 and GFCI 2 from
overload. If CB3 or CB4 opens, RC2 does
not work. 120 volts may still be present at
RC2. If CB4 opens, GFCI 2 does not work.
Press button to reset breaker.
If a circuit breaker continues to open,
contact Factory Authorized Service
Agent.
Maximum output from each 120 volt GFCI
receptacle is 2.4 kVA/kW. Maximum output
from each 240 volt duplex receptacle half is
4.0 kVA/kW.
Total combined output from all receptacles
is 4 kVA/kW.
EXAMPLE: If 12 A is drawn from RC1, only
9 A is available at GFCI 1:
(240 V x 12 A) + (120 V x 9 A) = 4.0 kVA/kW
Generator power
is not affected by
weld output.
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Routine Maintenance
Stop engine before maintaining.
Recycle
engine
fluids.
See Engine Manual and Maintenance Label for im-
portant start-up, service, and storage information.
Service engine more often if used in severe conditions.
*
To be done by Factory Authorized Service Agent.
Every 8 h
Wipe
Up
Spills.
Check Fluid
Levels. See
Section 5-5.
OIL
Full
FUEL
WATER
Drain Water
From Fuel
System. See
Section 8-4.
Every 50 h
Clean Air Filter.
See Section 8-3.
OM-494 Page 32
Clean And
Tighten
Weld
Terminals.
Every 100 h
Clean And
Tighten
Battery
Connections.
Change Oil
Filter. See
Section 8-4.
Change Oil. See
Section 8-4.
Check air cleaner
hoses for cracks
and loose clamps.
Every 200 h
Replace
Unreadable
Labels.
Every 250 h
Check And
Clean Spark
Arrestor. See
Section 8-9.
Every 500 h
Repair Or
Replace
Cracked
Cables.
Every 1000 h
OR
Blow Out Or
Vacuum Inside.
During Heavy
Service,
Clean Monthly.
Change Fuel
Filters. See
Section 8-4.
Service Welding
Generator Brushes
And Slip Rings.
Service More Often
In Dirty Conditions.*
1/2 in.
(13 mm)
Check Belt
Tension. See
Section 8-7.
FUEL
SLUDGE
Drain Sludge
From Fuel
Tank.*
Check
Valve
Clearance.*
OM-494 Page 33
8-2. Maintenance Label
OM-494 Page 34
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.
Optional
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 2/01 − ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-494 Page 35
8-4. Servicing Fuel And Lubrication Systems
9
Under Left Side
Of Fuel Tank Behind
Control Panel
1
2
3
4
Stop engine and let cool.
Oil Filter
Oil Drain Plug
Oil Drain Hose (Optional)
Oil Fill Cap
5
Primary Fuel Filter (Fuel/
Water Separator)
6
Petcock
7
Secondary Fuel Filter
8
Fuel Shutoff Valve Lever
9
Sludge Drain Plug
To change oil and filter:
See engine manual.
To drain water from fuel system:
Open primary fuel filter petcock and
drain water into metal container.
Close petcock when water-free fuel
flows.
7
To replace primary fuel filter:
Close shutoff valve and turn filter
counterclockwise. Remove filter.
Apply thin coat of fuel to gasket on
new filter. Install new filter and turn
clockwise. Open shutoff valve.
Bleed air from fuel system according to engine manual.
4
Inspect fuel line, and replace if
cracked or worn.
1
To replace secondary fuel filter:
See engine manual.
To drain sludge from fuel tank:
This procedure should only be
done by a Factory Authorized
Service Agent.
Remove Welder A (left) control
panel to access sludge drain plug.
Put metal container under drain and
remove plug. Reinstall plug when
sludge has drained.
2
Reinstall control panel.
Valve Open
After servicing, start engine
and check for fuel leaks.
8
I
Stop engine, tighten connections as necessary, and wipe
up spilled fuel.
Close doors.
3
2
O
5
6
Tools Needed:
3/8, 7/16, 3/4 in
Ref. 158 633-C / Ref. 190 377 / Ref. S-176 697
OM-494 Page 36
8-5. Adjusting Engine Speed
Engine Speed
(No Load)
Weld/Power
RPM
Engine speed is factory set and
should not require adjustment. After tuning engine, check engine
speed with tachometer. See table
for proper no load speed. If necessary, adjust speed as follows:
1850
1
High Speed Stop Screw
2
Lock Nut
Loosen nut. Turn screw out (toward
front of engine) several turns.
3
Linkage
4
Lock Nuts
Loosen nuts. Start engine and
move linkage until engine runs at
weld/power speed. Tighten nuts.
5
Stop engine.
5
Speed Control Lever
Turn screw in until screw touches
lever. Tighten lock nut on screw.
Close side door.
4
3
2
1
Right Side
Tools Needed:
3/8 in
Ref. 045 768-B
8-6. Servicing Optional Ether Starting Aid
Stop engine.
Improper handling or exposure to ether can harm your
health. Follow manufacturer’s safety instructions on
cylinder.
If engine does not start in cold
weather, check ether cylinder as
follows:
Remove cylinder from valve.
1
1
Ether Cylinder
2
Valve
3
Scale
Weigh cylinder to see if it is empty.
Be sure atomizer is not plugged and
valve fitting is clean.
Replace cylinder according to
Section 5-16.
3
33 oz
(935 g)
15 oz
(425 g)
Full
Empty
2
ether2 7/96 − 153 382-A / Ref. 190 377 / S-0692
OM-494 Page 37
8-7. Checking And Replacing Alternator Belt
Stop engine.
To check belt tension:
Remove rear panel.
1
Alternator V-Belt
2
Crank Pulley
3
Alternator Pulley
Place straight edge along top of pulleys. Pull down belt as far as it will
go, then measure distance from
belt to straight edge.
If measurement is less than 1/2 in
(13 mm), belt is okay. If not okay,
adjust belt tension.
To adjust belt tension:
4
Hex Nuts (2)
5
Alternator Bracket
Loosen nuts. Pivot alternator until
belt is tight. Tighten nuts. Recheck
tightness of belt. Readjust if
necessary.
Replace belt
cracked.
if
damaged
or
To replace belt:
Loosen hex nuts and pivot alternator clockwise. Remove belt.
4
Install new belt, pivot alternator until
belt is tight, and tighten nuts. Recheck tightness of belt after running
engine 15 minutes.
Reinstall rear panel.
3
5
1/2 in
(13 mm)
Max
1
2
Tools Needed:
1/2, 11/16 in
158 632 / Ref. 190 377
OM-494 Page 38
8-8. Resetting Fan Belt Safety Shutdown
Stop engine.
1
Cooling Fan V-Belt
See engine manual to replace or
tighten belt.
If belt breaks or becomes loose,
safety shutdown stops engine.
Correct problem, then reset safety
shutdown as follows:
2
Rod
3
Stop
4
Bracket
5
Handle
Pull handle towards front of unit until stop snaps in position behind
bracket.
Close door.
1
4
3
5
Right Side
2
Pull Handle To
Reset Shutdown
Tools Needed:
3/8 in
158 715 / Ref. 158 632 / Ref. 190 377
OM-494 Page 39
8-9. 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 several minutes to blow out cleanout hole. If
nothing blows out of hole, briefly
cover end of exhaust pipe with fireproof material.
3
2
1
Stop engine and let cool.
Reinstall cleanout plug.
Tools Needed:
3/8 in
Notes
Ref. 800 633-B / Ref. 190 377
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
OM-494 Page 40
8-10. Circuit Protection
Tools Needed:
3
1
4
2
7
8
5
6
9
Ref. 802 300 / Ref. 802 292-A
Stop engine.
When a circuit breaker or fuse opens,
it usually indicates a more serious
problem exists. Contact Factory Authorized Service Agent.
1 Fuse F1
2 Fuse F2
3 Fuse F3
4 Fuse F4
Open front panel.
Fuse F1 protects the exciter excitation
winding. If F1 opens, there is no weld or
generator power output on both sides.
Fuse F2 protects the exciter main field excitation winding. If F2 opens, there is no
weld output on both sides.
Fuse F3 protects Welder A (left) control
board PC1. If F3 opens, Welder A (left) weld
output stops.
Fuse F4 protects Welder B (right) control
board PC1. If F4 opens, Welder B (right)
weld output stops.
5 Circuit Breaker CB5
6 Circuit Breaker CB6
7 Circuit Breaker CB7
8 Circuit Breaker CB8
Circuit Breaker CB5 protects the 24 volt
and 115 volt ac output to Welder A (left) remote receptacle RC9. If CB5 opens, Welder A (left) RC9 24 and 115 volt ac output
stops.
Circuit Breaker CB6 protects the 24 volt
and 115 volt ac output to Welder B (right) remote receptacle RC8. If CB6 opens, Welder B (right) RC8 24 and 115 volt ac output
stops.
Circuit Breaker CB7 protects field current
regulator board PC4. If CB7 opens, weld
and generator power output on both sides
stops.
Circuit Breaker CB8 protects the generator
field flashing circuit. If CB8 opens, weld and
generator power output may continue if
generator maintains excitation. Weld and
generator power output stops if generator
requires field flashing circuit to restore excitation.
Press button to reset circuit breaker.
9 Fuses F11, F12, F13, F21, F22, F23
These fuses protect the weld stator windings. If fuse F11, F12, or F13 opens, Welder
B (right) side output is erratic or low. If fuse
F21, F22, or F23 opens, Welder A (left) side
output is erratic or low.
10 Thermostats TP3 And TP4 (Internal −
Not Shown)
Thermostat TP3 protects Welder A (left)
SR2 rectifier and TP4 protects Welder B
(right) SR3 rectifier from overheating. If
TP3 or TP4 opens, Welder A (left) or Welder
B (right) weld output stops and the High
Temp. Shutdown light goes on. Wait fifteen
minutes for module to cool and thermostat
to automatically reset. Reduce amperage,
voltage, or duty cycle before welding.
OM-494 Page 41
8-11. Troubleshooting
A. Welding
Trouble
Remedy
No weld output on either side; generator Place Output (Contactor) switches in On (Hot) position, or place switches in Remote position and connect
power output okay at ac receptacles.
remote contactors to remote receptacles RC8 and RC9 (see Section 6-3).
Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP3 and
TP4 to reset (see Section 8-10).
Check position of Process Selector switches and Welder Selector switch. All weld output stops if
either Process Selector switch is placed in CV position when Welder Selector switch is in Welder B
position (see Sections 6-1 and 6-3).
Check fuse F2, and replace if open (see Section 8-10). Have Factory Authorized Service Agent
check field current regulator board PC4.
Have Factory Authorized Service Agent check field current regulator board PC4 and Welder Selector
switch S2.
No weld output on either side and no Disconnect equipment from generator power receptacles during start-up.
generator power output at ac receptacles.
Check fuse F1, and replace if open (see Section 8-10).
Reset circuit breakers CB7 and/or CB8 (see Section 8-10).
Have Factory Authorized Service Agent check brushes and slip rings, field excitation circuit, rotor, stator,
and field current regulator board PC4.
No Welder A (left) weld output; Welder B Check fuse F3, and replace if open (see Section 8-10).
(right) weld output okay.
Check position of Welder Selector switch. Welder A (left) weld output stops when Welder Selector
switch is placed in Welder B position (see Section 6-1).
Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP3 to
reset (see Section 8-10).
Have Factory Authorized Service Agent check Welder A (left) contactor circuit.
No Welder B (right) weld output; Welder Check fuse F4, and replace if open (see Section 8-10).
A (left) weld output okay;
Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP4 to
reset (see Section 8-10).
Have Factory Authorized Service Agent check Welder B (right) contactor circuit.
Low Welder A (left) weld output; Welder B (right) output okay.
Check position of Process Selector switch (see Section 6-3).
Increase Amperage/Voltage control setting.
Check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have Factory Authorized
Service Agent check main rectifier SR2.
Have Factory Authorized Service Agent check main rectifier SR2, synchronization transformers T5,
T6 and T7, and control board PC1.
Low Welder B (right) weld output;
Welder A (left) weld output okay.
Check position of Process Selector switch (see Section 6-3).
Increase Amperage/Voltage control setting.
Check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have Factory Authorized
Service Agent check main rectifier SR3.
Have Factory Authorized Service Agent check main rectifier SR3, synchronization transformers T8,
T9 and T10, and control board PC5.
OM-494 Page 42
Trouble
Low weld output on both sides.
Remedy
Check engine speed, and adjust if necessary (see Section 8-5).
Check position of Process Selector switch(s) (see Section 6-3).
Increase Amperage/Voltage controls settings.
Have Factory Authorized Service Agent check field current regulator board PC4.
High weld output on both sides.
Have Factory Authorized Service Agent check field current regulator board PC4.
Erratic weld output on either side.
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.
Check Process Selector switch(s) connections and contacts.
Welder A (left) side: check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have
Factory Authorized Service Agent check main rectifier SR2.
Welder B (right) side: check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have
Factory Authorized Service Agent check main rectifier SR3.
Have Factory Authorized Service Agent check Welder Selector switch S2.
Low open-circuit voltage on both sides.
Check engine speed, and adjust if necessary (see Section 8-5).
Have Factory Authorized Service Agent check field current regulator board PC4.
Low open-circuit voltage on either side.
Increase Amperage/Voltage control setting.
Welder A (left) side: check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have
Factory Authorized Service Agent check main rectifier SR2.
Welder B (right) side: check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have
Factory Authorized Service Agent check main rectifier SR3.
Have Factory Authorized Service Agent check main rectifiers SR2 and SR3, synchronization transformers T5 thru T10, and control board PC1 or PC5.
No control of weld output on either
side.
Place A/V Control switch in Panel position, or place switch in Remote position and connect remote
control to remote receptacle RC8 or RC9 (see Sections 5-17 and 6-3).
Have Factory Authorized Service Agent check control board PC1 or PC5.
No voltage control on either side; open- Repair or replace remote device.
circuit voltage present.
Place A/V Control switch in Panel position, or place switch in Remote position and connect remote
control to remote receptacle RC8 or RC9 (see Sections 5-17 and 6-3).
Check connections to Remote receptacle RC8 and RC9.
Have Factory Authorized Service Agent check control board PC1 or PC5.
Wire feeder does not work (either side). Reset Welder A (left) circuit breaker CB5 or Welder B (right) circuit breaker CB6 (see Section 8-10).
Check position of Process Selector switches and Welder Selector switch. All weld output stops if
either Process Selector switch is placed in CV position when Welder Selector switch is in Welder B
position (see Sections 6-1 and 6-3).
Check connections to Remote 14 receptacle RC8 (see Section 5-17).
Place optional Polarity switches in Reverse position. There is no CV weld output when Polarity switch
is in Straight position.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Repair or replace wire feeder.
OM-494 Page 43
B. Generator Power
Trouble
Remedy
No output at generator power ac recep- Reset receptacle circuit breakers (see Section 7-1).
tacles.
Press GFCI reset button on 120 volt GFCI receptacles (see Section 7-1).
Check fuse F1, and replace if open (see Section 8-10).
Check receptacle(s) for continuity and proper connections. Replace receptacle(s) if necessary.
Have Factory Authorized Service Agent check brushes and slip rings.
High or low output at generator power ac Check engine speed, and adjust if necessary (see Section 8-5).
receptacles.
C. Engine
Trouble
Engine will not crank.
Remedy
Check battery voltage, and replace battery if necessary.
Check battery connections and tighten if necessary.
Have Factory Authorized Service Agent check Engine Start Button PB1.
Engine cranks but does not start.
Check fuel level (see Section 5-5).
Open fuel valve (see Section 5-5).
Check battery voltage, and replace battery if necessary.
Check blower fan V-belt according to engine manual. Safety shutdown stops engine if belt is broken or
loose (see Section 8-8).
Check engine charging system according to engine manual.
See engine manual.
Engine suddenly stops.
Check blower fan V-belt according to engine manual. Safety shutdown stops engine if belt is broken or
loose (see Section 8-8).
See engine manual.
Battery discharges between uses.
Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator and connections according to engine manual.
Engine uses oil during run-in period; Dry engine (see Section 10).
wetstacking occurs.
OM-494 Page 44
Notes
OM-494 Page 45
SECTION 9 − ELECTRICAL DIAGRAMS
Figure 9-1. Circuit Diagram For Welding Generator
OM-494 Page 46
210 657-A
OM-494 Page 47
SECTION 10 − RUN-IN PROCEDURE
run_in3 8/01
10-1. Wetstacking
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
1
2
Run diesel engines near rated voltage and current during run-in period
to properly seat piston rings and
prevent wetstacking. See nameplate, rating label, or specifications
section in this manual to find rated
voltage and current.
1
Welding Generator
2
Do not idle engine longer than
necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generator is kept loaded during
run-in.
Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional engine run-in information.
OM-494 Page 48
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.
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
4
2
1
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 Welder Selector switch in
Welder B position (600 Amps), A/V
control in minimum position, and
both Process Selector switches in
Stick/TIG position.
3 Weld Cables
Connect load bank to generator
Welder B (right) 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 350 Amps at 40 volts.
3
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
Check oil level frequently during run-in; add oil if needed.
After one hour (minimum) place A/V
control in minimum position, then
turn off load bank to remove load.
Run engine several minutes at no
load.
Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0683
OM-494 Page 49
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.
6
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
2
1 Resistance Grid
Use grid sized for generator rated
output.
1
Turn Off grid.
2 Welding Generator
Place Welder Selector switch in
Welder B position (600 Amps), A/V
control in minimum position, and
both Process Selector switches in
Stick/TIG position.
3 Weld Cables
Connect grid to generator Welder B
(right) weld output terminals using
proper size weld cables with correct connectors (polarity is not important).
4
Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
3
5
Start engine and run for several
minutes.
Set grid switches and then adjust
generator A/V control so load
equals 350 Amps at 40 volts.
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-494 Page 50
SECTION 11 − GENERATOR POWER GUIDELINES
NOTE
The views in this section are intended to be representative of all engine-driven
welding generators. Your unit may differ from those shown.
11-1. Selecting Equipment
1
2
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
Do not use 2-prong plug unless equipment is double insulated.
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577
11-2. Grounding Generator To Truck Or Trailer Frame
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
1
2
1
GND/PE
3
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
2
3
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Electrically bond generator
frame to vehicle frame by
metal-to-metal contact.
Bed liners, shipping skids, and some running
gear insulate the welding generator from the vehicle frame. Always connect a ground wire from
the generator equipment grounding terminal to
bare metal on the vehicle frame as shown.
S-0854
OM-494 Page 51
11-3. Grounding When Supplying Building Systems
1
1
2
Equipment Grounding
Terminal
Grounding Cable
2
GND/PE
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
2
Use ground device as stated
in electrical codes.
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-494 Page 52
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-494 Page 53
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-494 Page 54
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-494 Page 55
11-10. Typical Connections To Supply Standby Power
Properly install and ground this equipment according to
its Owner’s Manual and national, state, and local codes.
1
2
Utility
Electrical
Service
3
Transfer Switch
4
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
5
Essential
Loads
Have only qualified persons perform
these connections according to all
applicable codes and safety practices.
Switch transfers the electrical load from
electric utility service to the generator. Transfer load back to electric utility when service is
restored.
Properly install and ground this
equipment according to its Owner’s
Manual and national, state, and local
codes.
Install correct switch (customer-supplied).
Switch rating must be same as or greater
than the branch overcurrent protection.
Customer-supplied
equipment is required if generator will supply standby
power during emergencies or power outages.
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
3 Fused Disconnect Switch
Install correct switch (customer-supplied) if
required by electrical code.
4 Welding Generator Output
Generator output voltage and wiring must be
consistent with regular (utility) system voltage and wiring.
Connect generator with temporary or permanent wiring suitable for the installation.
Turn off or unplug all equipment connected to
generator before starting or stopping engine.
When starting or stopping, the engine has
low speed which causes low voltage and
frequency.
5 Essential Loads
Generator output may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
requirements, connect only essential loads
(pumps, freezers, heaters, etc. − See Section 11-4).
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-494 Page 56
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-494 Page 57
SECTION 12 − PARTS LIST
Hardware is common and
not available unless listed.
21
20
22
19
5
23
6
7
8
9
4
24
25−SEE FIG 12-4
18
10
3
11
2
12
13
9
10
1
103
16
17
28
26
14 15
27
30
10
9
96−SEE FIG 12-2
31
32
102
34
101
35
36
37
38
98
99
100
83
95
97
84
85
94
86
87
92
91
90
89
88
93
Figure 12-1. Main Assembly
OM-494 Page 58
33
50
48
47
49
46
45
44
51
43
52
53
54
46
40
55
39
56
41
58
57−SEE FIG 12-3
59
42
60
82
61
81
63
80
64
79
35
62
34
65
67
66
68
69
78−SEE FIG 12-4
36
70
37
77
76
71
75
74
73
72
802 317-D
OM-494 Page 59
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
1 . . . . . . . . . . . . . 605 288
2 . . . . . . . . . . . . . 070 010
3 . . . . . . . . . . . . . 088 696
4 . . . . . . . . . . . . . 134 771
5 . . . . . . . . . . . . . 184 675
6 . . . . . . . . . . . . . 182 022
7 . . . . . . . . . . . . . 020 185
8 . . . . . . . . . . . . . 053 525
9 . . . . . . . . . . . . . 172 071
10 . . . . . . . . . . . . 134 835
11 . . . . . . . . . . . . 097 507
12 . . . . . . . . . . . . 175 432
13 . . . . . . . . . . . . 039 599
14 . . . . . . . . . . . +048 227
15 . . . . . . . . . . . . 170 689
16 . . . . . . . . . . . +170 617
17 . . . . . . . . . . . . 017 479
18 . R3, R5 . . . 097 459
19 . . . . . . . . . . . . 108 081
20 . . . . . . . . . . . . 182 276
21 . . . . . . . . . . . . 208 353
22 . . . . . . . . . . . . 032 453
23 . . . . . . . . . . . . 190 896
24 . . . . . . . . . . . . 010 460
25 SR2, SR3 Figure 12-5
26 . . . . . . . . . . . . 176 697
27 . . . . . . . . . . . . 145 282
28 . . . . . . . . . . . . 083 859
29 . . . . . . . . . . . . Deleted
30 . . . . . . . . . . . . 202 242
31 . . . . . . . . . . . . 192 744
32 . . . . . . . . . . . . 135 205
33 . . . . . . . . . . . . 116 707
34 . . . . . . . . . . . . 119 849
35 . . . . . . . . . . . . 071 731
36 . . . . . . . . . . . . 071 890
37 . . . . . . . . . . . . 071 730
38 . . . . . . . . . . . . 072 848
39 . . . . . . . . . . . . 010 875
40 . . . . . . . . . . . . 105 734
41 . . . . . . . . . . . . 176 232
42 . . . . . . . . . . . . 048 216
43 . . . . . . . . . . . +105 909
44 . . . . . . . . . . . . 107 990
45 . . . . . . . . . . . . 035 968
46 . . . . . . . . . . . . 158 610
47 . . . . . . . . . . . . 168 385
48 . . . . . . . . . . . +192 313
49 . . . . . . . . . . . . 108 487
50 . . . . . . . . . . . . 117 257
51 . . . . . . . . . . . +192 314
52 . . . . . . . . . . . . 181 642
53 . . . . . . . . . . . . 004 130
54 . . . . . . . . . . . . 087 341
55 . . . . . . . . . . . . 087 336
56 . . . . . . . . . . . . 027 434
57 . . . . . . . . . Figure 12-3
58 . . . . . . . . . . . . 023 313
59 . . . . . . . . . . . . 201 547
60 . . . . . . . . . . . . 010 863
OM-494 Page 60
. . FITTING, pipe galv plug sqhd .250NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BOLT, J stl .250-20 x 2.750 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . STRAP, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . PLUG, protective .640sq . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . TANK, fuel 22.3gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CAP, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FITTING, pipe brs elbow st 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FITTING, hose brs barbed M 5/16tbg x 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . 1
. . CLAMP, hose .520-.605clp dia slfng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . HOSE, SAE .312 ID x .560 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . 9ft
. . STRIP, rbr adh back .125 x 1.000 x 20.500 60 duro . . . . . . . . . . . . . . . . . . . . 2
. . VALVE, shut-off fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FITTING, brs barbed M 5/16 tbg x 1/4 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . UPRIGHT, base front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FRAME, mtg reactor and fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . UPRIGHT, base center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RESISTOR, WW fxd 375W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BATTERY, stor 12v 660 crk 110 rsv gp 24 low . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STUD, stl .312-18 x 10.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT . . . . . . . . . . . . . . . . 2
. . BRACKET, mtg fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.....................................................................
. . BASE, fuel filter assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SEPARATOR, fuel filter & water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . NUT, 625-11 .94 hex .76H stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . SUPPORT, front engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SCREW, 625-11 x 4.00 hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . WASHER, flat stl .656 ID x 2.250 OD x .187thk . . . . . . . . . . . . . . . . . . . . . . . 4
. . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 50 dur . . . . . . . . . . . . . . 2
. . CLAMP, muffler 2.000 dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PIPE, muffler extension elbow 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BAFFLE, air muffler exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, mtg breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . WASHER, flat rbr 3.625 ID x 5.875 OD x .062thk . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . LABEL, warning battery explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . PANEL, end engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, diesel engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, support door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . BUMPER, door 1.000 OD x .750 high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . LABEL, welder will not start by applying power to terminals . . . . . . . . . . . . . 2
. . SIDE CONTROL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . CLAMP, hose 3.250-3.000 clp dia slftg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOSE, air cleaner w/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CLAMP, hose 2.062 − 3.000 clp slftg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . 61 . . . . . . . . . . . . 189 764 . . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *192 938 . . FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . *♦192 939 . . FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 203 462 . . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 62 . . . . . . . . . . . . 165 785 . . HOSE, air cleaner 2.437 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 63 . . . . . . . . . . . . 048 213 . . BAFFLE, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 194 467 . . WASHER, flat (for baffle) 6.25 ID x 11.50 OD x .62 T buna . . . . . . . . . . . . . 1
. . 64 . . . . . . . . . . . . . . . . . . . . . . . LEVER, trip shutdown (included w/engine − see engine parts list) . . . . . . . 1
. . 65 . . . . . . . . . . . . . . . . . . . . . . . SPRING (included w/engine − see engine parts list) . . . . . . . . . . . . . . . . . . . 1
. . 66 . . . . . . . . . . . . 181 634 . . ENGINE, dsl electric (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 67 . . . . . . . . . . . . 087 371 . . . . ROD, shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *064 677 . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *062 342 . . FILTER, fuel primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *064 686 . . FILTER, fuel secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *064 690 . . BELT, blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 68 . . . . . . . . . . . . 070 661 . . ROD, speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 69 . . . . . . . . . . . . 151 969 . . SWITCH, pressure 4PSI N/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 70 . . . . . . . . . . ♦047 361 . . FITTING, banjo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 71 . . . . . . . . . . ♦089 351 . . FITTING, pipe brs plug hexhd 1/2NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 72 . . . . . . . . . . ♦192 197 . . BRACKET, mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 73 . . . . . . . . . . . ♦008 114 . . HOSE, oil w/fittings 17.500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 74 . . . . . . . . . . ♦047 234 . . BOLT, banjo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦047 235 . . WASHER, oil seal copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 75 . . . . . . . . . . . . 127 994 . . BALL JOINT, .250-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 76 . . . . . . . . . . . . 162 740 . . STUD, stl .250-28 x 45.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 77 . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 60 dur . . . . . . . . . . . . . . 2
. . 78 . . . . . . . . . Figure 12-4 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 79 . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 80 . . . . . . . . . . . . 176 236 . . BAFFLE, air outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 81 . . . . . . . . . . . . . . . . . . . . . . . CLAMP, muffler (included with engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 82 . . . . . . . . . . . . 105 733 . . PIPE, muffler extension elbow 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 83 . . . . . . . . . . . . 165 739 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 84 . . . . . . . . . . . . 191 446 . . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . . . 2.1ft
. . 85 . . . . . . . . . . . . 173 352 . . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . 2.4ft
. . 86 . . . . . . . . . . . . 192 305 . . TRAY, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 87 . . . . . . . . . . . . 176 167 . . NUT, 250-20 acorn nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 88 . . . . . . . . . . . . 192 303 . . ANGLE, mtg stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 89 . Z1, Z2 . . . 192 296 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 90 . . . . . . . . . . . . 205 791 . . BRACKET, mtg fuse assembly (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 91 . . . . . . . . . . . . 204 965 . . . . STRIP, insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 92 . . . . . . . . . . . . . 026947 . . . . STAND-OFF, insul .250-20 x 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . 93 F11-13, F21-23 . 027 267 . . FUSE, link 300 A 250 volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 94 . . . . . . . . . . . . 192 304 . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 95 . . . . . . . . . . . . 134 792 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 96 . . . . . . . . . Figure 12-2 . . FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 97 . . . . . . . . . . . . 175 256 . . INSULATOR, side rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 98 . . . . . . . . . . . . 192 300 . . SHROUD, generator LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 99 . T2, T4 . . . 192 371 . . TRANSFORMER, 115V pri 24VCT 8A w/leads . . . . . . . . . . . . . . . . . . . . . . . . 2
. 100 . . . . . . . . . . . . 192 301 . . SHROUD, generator RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 101 . . . . . . . . . . . . 168 829 . . TRANSDUCER, current 1000A module max open loop . . . . . . . . . . . . . . . . 2
. 102 . . . . . . . . . . . . 192 299 . . SHROUD, generator center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 103 . . . . . . . . . . . . 194 021 . . CAPACITOR ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . 162 817 . . . . BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . C15, C20 . . 163 535 . . . . CAPACITOR, elctlt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . R4, R6 . . . 140 002 . . . . RESISTOR, WW fxd 10W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 162 799 . . . . BRACKET, mtg capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OM-494 Page 61
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . . 193 501 . . KIT, label (includes safety and informational labels) . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label
individually or as part of Label Kit 193 501
*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.
Hardware is common and
not available unless listed.
6
7
2
8
9
5
4
12
1
13
14
11
10
15
16
42
28
29
41
22
13
27
30
26
18
40
25
24
39
35
38
37
12
21
17
2
23
36
22
30
34
33
32
21
20
19
18
31
802 318-C
Figure 12-2. Front Panel
OM-494 Page 62
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-2. Front Panel (Figure 12-1 Item 96)
. . 1 . . . . . . . . . . . . . . 209056 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 2 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 3 . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 4 . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and serial number) . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . 190 375 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 216270 . . PANEL, aux power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 192 334 . . HARNESS, wiring aux power panel (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . 7 . GFCI1,2 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . . . 2
. . 8 . . CB1-4 . . . 093 996 . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . . . 4
. . 9 . RC1, RC2 . . 193 257 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 250V . . . . . . . . . . . . . . . . . . . . . . 2
. . 10 . . R10 . . . . 189 699 . . RESISTOR, WW tap 375W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . 038 620 . . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 12 . TE1,2 . . . . 038 621 . . BLOCK, term 30A 4 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 13 . T5 - 10 . . . 210 636 . . TRANSFORMER, control 6VA 120VCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 14 . . PC4 . . . . 191 255 . . CIRCUIT CARD ASSEMBLY, field current regulator . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . 083 147 . . GROMMET, SCR NO 8/10 panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 16 . . . . . . . . . . . . 192 332 . . PANEL LAYOUT, mtg component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . CB7,8 . . . . 139 266 . . CIRCUIT BREAKER, man reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 18 . . 1T,2T . . . . 190 210 . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . . . . . . . . . . . 083 030 . . STUD, brs .250-20 x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . 010 381 . . CONNECTOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . T1, T3 . . . 192 367 . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 22 . . . . . . . . . . . . 184 649 . . HOLDER, fuse mintr .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 23 . . F3,4 . . . *012 643 . . FUSE, mintr gl slo-blo 1A, 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 24 . . F1,2 . . . *125 847 . . FUSE, mintr cer slo-blo 12A, 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 25 . . . . . . . . . . . . 129 351 . . SCREW, 008−32x .50 hexwhd.34d stl pld slffmg tap−rw . . . . . . . . . . . . . . . . 2
. . 26 . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . C1 . . . . . 087 110 . . CAPACITOR, elctlt 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . SR1 . . . . 035 704 . . RECTIFIER, integ bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 195 702 . . HARNESS, wiring componet panel (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 188 512 . . . . . SEAL, wire univ 6P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . 187 651 . . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . RC13,21 . . 116 045 . . . . . HOUSING, plugs and pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG17 . . . 135 275 . . . . . HOUSING, plugs and pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . RC19, PLG20 . 168 071 . . . . . HOUSING, plugs and pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . S2 . . . . . 192 292 . . SWITCH, paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 192 006 . . HARNESS, engine (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 30 . . PB1 . . . . 046 433 . . . . SWITCH, PB MC NO SPST 35A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 31 . . . . . . . . . . . . . . . . . . . . . . . STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . . HM . . . . . 145 247 . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . . . . . . . . . . 205 744 . . ROD, engine shutoff assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 34 . . . . . . . . . . . . 019 603 . . KNOB, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 35 . . PL1 . . . . . 188 266 . . LIGHT, ind red lens 13V (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 36 . . . . . . . . . . . . 082 788 . . . . HOLDER, light ind only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 37 . . . . . . . . . . . . 048 155 . . . . BULB, incand min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 38 . . . . . . . . . . . . 082 789 . . . . LENS, light ind red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 40 . . . . . . . . . . . . 111 785 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and serial number) . . . . . . . . . 1
. . 42 . . . . . . . . . . . . 192 316 . . PANEL, front control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 193 501
*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-494 Page 63
Hardware is common and
not available unless listed.
1
30
31
32
29
33
2
34
28
27
7
26
3
8
6
5
4
9
10
11
25
24
14
23
13
35
22
21
12
36
15
20
19
18
16
17
802 320-A
Figure 12-3. Side Control Panels − Welder B (Right) Side Shown
OM-494 Page 64
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-3. Side Control Panels (Figure 12-1 Item 57)
. . 1 . . . . . . . . . . . . +192 330 . . PANEL, side output RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . +192 325 . . PANEL, side output LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 2 . . . . . . . . . . . . . 027 434 . . LABEL, welder will not start by applying power to terminals . . . . . . . . . . . . .
. . 3 . . . . . . . . . . . . . 010 828 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 4 . . . . . . . . . . . . . 086 074 . . TUBING, cop .540 ID x .123 wall x .562 − welder A (left) side only . . . . . . .
. . 5 . . S1, S9 . . . 204 903 . . SWITCH, mode single w/ dust cover (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 163 557 . . . . SWITCH, mode single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 202 881 . . . . COVER, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 6 . . . . . . . . . . . . . 193 337 . . ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 7 . . . PC5 . . . . 204 832 . . CIRCUIT CARD ASSEMBLY, welder B (right) side control . . . . . . . . . . . . . .
. . . . . . . . PC1 . . . . 204 835 . . CIRCUIT CARD ASSEMBLY, welder A (left) side control . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 192 218 . . HARNESS, wiring control box welder B (right) (consisting of) . . . . . . . . . . .
. . 8 . . . CR3 . . . . 000 770 . . . . RELAY, encl 24VDC 3PDT 10A/120VAC 11 pin . . . . . . . . . . . . . . . . . . . . .
. . 9 . . . GRD . . . . 185 011 . . . . STUD, primary board brs 10-32 x 1.592 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 10 S8,10,11 . . 011 609 . . . . SWITCH, tgl SPDT 15A 125VAC on-none-on . . . . . . . . . . . . . . . . . . . . . . .
. . 11 . . R7,8 . . . . 035 897 . . . . POTENTIOMETER, cp std slot 1t 2w 1k linear . . . . . . . . . . . . . . . . . . . . . .
. . 12 . LS3, 4 . . . 089 645 . . . . SWITCH, lim 11A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . PLG27 . . . 131 056 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 187 651 . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . PLG20 . . . 168 071 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . PLG9,26 . . 148 439 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . PLG12 . . . 152 249 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . PLG10 . . . 153 501 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . RC22 . . . . 168 845 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . RC23 . . . . . 168846 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG8 . . . . 169 240 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 192 208 . . HARNESS, wiring control box welder A (left) (consisting of) . . . . . . . . . . . .
. . . . . . . . CR2 . . . . 000 770 . . . . RELAY, encl 24VDC 3PDT 10A/120VAC 11 pin . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . GRD . . . . 185 011 . . . . STUD, primary board brs 10-32 x 1.592 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . S3,6,7 . . . 011 609 . . . . SWITCH, tgl SPDT 15A 125VAC on-none-on . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . R1,8 . . . . 035 897 . . . . POTENTIOMETER, cp std slot 1t 2w 1k linear . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . LS1,2 . . . . 089 645 . . . . SWITCH, lim 11A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . PLG18 . . . 131 056 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 187 651 . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . PLG19 . . . 168 071 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . PLG4,11 . . 148 439 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG5 . . . . 152 249 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . PLG10 . . . 153 501 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . RC6 . . . . 168 845 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . RC7 . . . . . 168846 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG3 . . . . 169 240 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . .
. . 13 PC2, PC6 . . 178 130 . . CIRCUIT CARD ASSEMBLY, digital meter . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 14 . . . . . . . . . . . . 165 316 . . STAND-OFF, No. 6-32 x .875 lg .312 hex nyl . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 136 343 . . SCREW, K50 x 20 soc hd trx stl pld slftpg . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 15 . . . . . . . . . . . . 097 924 . . KNOB, pointer 1.625dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 16 . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 17 . . . . . . . . . . . . 097 922 . . KNOB, pointer .875dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 18 . . . . . . . . . . . . 148 956 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 19 . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE (order by model and serial number) . . . . . . . . . . . . . . . . . . . . .
. . 20 . . . . . . . . . . . . 162 815 . . PANEL, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 21 . . . . . . . . . . . . 161 297 . . CAM, switch selector 2posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 22 . . . . . . . . . . . . 170 391 . . CONNECTOR, circ protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 23 . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 039 049 . . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 039 044 . . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 601 976 . . . . SCREW, 500-13 x 1.50 hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 601 880 . . . . NUT, 500-13 x .75 hex .31H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
1
2
1
1
2
1
1
1
1
1
3
2
2
1
1
1
2
1
1
1
1
1
1
1
1
3
2
2
1
1
1
2
1
1
1
1
1
2
8
8
2
6
2
2
2
2
2
1
4
1
1
1
1
OM-494 Page 65
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-3. Side Control Panels (Continued)
. . 24 . . . . . . . . . . . . 039 046
. . . . . . . . . . . . . . . . . . 039 045
. . . . . . . . . . . . . . . . . . 039 044
. . . . . . . . . . . . . . . . . . 601 976
. . . . . . . . . . . . . . . . . . 601 880
. . 25 . . . . . . . . . . . . 192 494
. . 26 . . . . . . . . . . . . 192 493
. . 27 C2,4,5,21,22,23 . 136 736
. . . . . . . . . . . . . . . . . . 192 336
. . 28 . . . 4T . . . . . 190 210
. . 29 . . CB6 . . . . 139 266
. . 30 . . RC9 . . . . 134 735
. . 31 . . PC7 . . . . 181 261
. . . . . . . PLG24 . . . 115 094
. . . . . . . PLG22 . . . 168 847
. . . . . . . PLG23 . . . 152 249
. . . . . . . PLG21 . . . 135 556
. . . . . . . . . . . . . . . . . . 188 512
. . . . . . . . . . . . . . . . . . 192 337
. . . . . . . . . 3T . . . . . 190 210
. . . . . . . . CB5 . . . . 139 266
. . . . . . . . RC8 . . . . 134 735
. . . . . . . . PC3 . . . . 181 261
. . . . . . . PLG14 . . . 115 094
. . . . . . . . PLG6 . . . . 168 847
. . . . . . . . PLG3 . . . . 152 249
. . . . . . . PLG13 . . . 135 556
. . . . . . . . . . . . . . . . . . 188 512
. . 32 . . . . . . . . . . . . 165 316
. . . . . . . . . . . . . . . . . . 145 217
. . 33 . . . . . . . . . . ♦059 773
. . 34 . . . . . . . . . . ♦010 647
. . . . . . . . . . . . . . . . ♦091 067
. . . . . . . . . . . . . . . . ♦168 077
. . . . . . . . . . . . . . . . ♦199 123
. . . . . . . . . . . . . . . . ♦199 124
. . 35 PL2, PL3 . . 159 522
. . 36 . . . . . . . . . . . . 159 036
. . TERMINAL, pwr output black (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TERMINAL BOARD, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, 500-13 x 1.50 hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, 500-13 x .75 hex .31H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, bus bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HARNESS, wiring unit welder B (right) (consisting of) . . . . . . . . . . . . . . . . . .
. . . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT BREAKER, man reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, circ MS/CPC 14skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSEMBLY, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING, plug and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SEAL, wire univ 6P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HARNESS, wiring unit welder A (left) (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT BREAKER, man reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, circ MS/CPC 14skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSEMBLY, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING, plug and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SEAL, wire univ 6P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, No. 6-32 x .875 lg .312 hex nyl . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, K40 x 12 pan hd phl stl pld slftpg . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIN, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, tw lk insul fem (Dinse-type) to output stud . . . . . . . . . . . . .
. . LABEL, component identification master polarity . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, component identification slave polarity . . . . . . . . . . . . . . . . . . . . . . . .
. . LED, yellow 2.1v 20 ma 45.0 mcd panel mtg .250 hole . . . . . . . . . . . . . . . . .
. . LENS, led clear panel mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
1
1
1
2
6
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
6
2
2
2
6
1
1
2
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label
individually or as part of Label Kit 193 501
*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-494 Page 66
Hardware is common and
10
1
2
3
4
5
15
14
6
13
7
12
9
8
11
not available unless listed.
Ref. 048 456-E
Figure 12-4. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-4. Generator (Figure 12-1 Item 78)
..
..
..
..
..
..
..
..
..
..
..
..
1 . . . . . . . . . . . . *151 299
2 . . . . . . . . . . . . . 188 387
3 . . . . . . . . . . . . . 600 270
4 . . . . . . . . . . . . . 152 044
5 . . . . . . . . . . . . . 173 066
6 . . . . . . . . . . . . +205 600
7 . . . . . . . . . . . . . 039 207
8 . . . . . . . . . . . . . 192 286
9 . . . . . . . . . . . . . 024 617
10 . . . . . . . . . . . . 053 390
11 . . . . . . . . . . . . 083 748
12 . . . . . . . . . . . . 013 367
. . BRUSH, contact elect clrg .375 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRUSHHOLDER/BRACKET ASSEMBLY, (consisting of) . . . . . . . . . . . . . . .
. . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAP, holder brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BAFFLE, air generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROTOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RING, retaining external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1
3
3
1
1
1
1
1
1
1
2
OM-494 Page 67
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-4. Generator (Continued)
. . 13 . . . . . . . . . . . . 195 704 . . STATOR, exciter aux pwr 120/240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . 173 068 . . ENDBELL, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . 143 220 . . . . O-RING 2.859ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 193 501
*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.
Hardware is common and
not available unless listed.
1
802 319
Figure 12-5. Rectifier Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-5. Rectifier (Figure 12-1 Item 25)
. . 1 . . . . . . . . . . . . . 205 613 . . RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 203 001 . . RECTIFIER, Si Diode (One Side Service kit W/Varnish Coating) . . . . . . . . 1
. . . . . PLG1, PLG2 . 158 720 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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-494 Page 68
Notes
OM-494 Page 69
Effective January 1, 2005
(Equipment with a serial number preface of “LF” 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.
*
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
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’s True Blue Limited Warranty shall not apply to:
1.
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.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
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 Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
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 1/05
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
Contact 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
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
www.MillerWelds.com
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
 2005 Miller Electric Mfg. Co.
1/05
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