Miller Electric TRAILBLAZER PRO 350 D Owner Manual

OM-4413
207 948D
July 2003
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Plasma Cutting and Gouging
with Spectrum Unit
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
Trailblazer Pro 350 D
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog orindividual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
WARNING
Battery posts, terminals
and related accessories
contain lead and lead
compounds, chemicals
known to the State of
California to cause
cancer and birth defects
or other reproductive
harm. Wash hands after
handling.
CALIFORNIA
Proposition 65
Warning
Diesel engine exhaust
and some of its constituents are known to
the State of California to
cause cancer, birth
defects, and other
reproductive harm.
The following terms are
used interchangeably
throughout this manual:
MIG = GMAW, Wire Welding
TIG = GTAW
Stick = SMAW
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. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. CC Stick Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. CC TIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. DC/CV MIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Adding Coolant To Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Operating Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Remote 14 Receptacle RC4 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Guidelines For Installing Customer-Supplied Emergency Air Shutdown Valve . . . . . . . . . . .
SECTION 5 – OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Description Of Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Recommendations For Extreme Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Typical Stick Welding Connections And Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Typical MIG Welding Connections And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Typical MIG Connections And Settings Using Weld Control And Spoolgun . . . . . . . . . . . . . .
5-9. Typical DC Scratch Start TIG Connections And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Typical AC TIG (With High Frequency Unit) Connections And Settings . . . . . . . . . . . . . . . . .
5-11. Typical Carbon Arc Cutting (CAC-A) Connections And Settings . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Generator Power Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Servicing Engine Lubrication And Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Replacing Throttle Solenoid TS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 – RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 – GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
35
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SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING
rom _nd_10/02
Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-6. Read and follow all
Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present
on unit.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground — check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first – double-check connections.
Frequently inspect input power cord for damage or bare wiring —
replace cord immediately if damaged — bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverters after
stopping engine.
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-4413 Page 1
BUILDUP OF GAS can injure or kill.
FLYING METAL can injure eyes.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
ARC RAYS can burn eyes and skin.
HOT PARTS can cause severe burns.
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.
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.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
MAGNETIC FIELDS can affect pacemakers.
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.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
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.
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.
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
BATTERY EXPLOSION can BLIND.
FUEL can cause fire or explosion.
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.
OM-4413 Page 2
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.
MOVING PARTS can cause injury.
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (–) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
Wear safety glasses and gloves and put a rag over radiator cap.
ENGINE EXHAUST GASES can kill.
Use equipment outside in open, well-ventilated
areas.
If used in a closed area, vent engine exhaust
outside and away from any building air intakes.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
Turn cap slightly and let pressure escape slowly before
completely removing cap.
1-4. Compressed Air Hazards
BREATHING COMPRESSED AIR can
cause serious injury or death.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
COMPRESSED AIR can cause injury.
HOT PARTS can cause burns and injury.
Wear approved safety goggles.
Do not direct air stream toward self or others.
Do not touch hot compressor or air system
parts.
Let system cool down before touching or
servicing.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
Release air pressure from tools and system
before servicing, adding or changing attachments, or opening compressor oil drain or oil
fill cap.
READ INSTRUCTIONS.
Read Owner’s Manual before using or servicing unit.
Stop engine and release air pressure before
servicing.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, trailer, or any other
accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or
stopping engine.
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
OM-4413 Page 3
FLYING SPARKS can cause injury.
H.F. RADIATION can cause interference.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
Use only genuine MILLER/Hobart replacement
parts.
Perform engine and air compressor (if applicable) maintenance and service according to this
manual and the engine/air compressor (if applicable) manuals.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
Electromagnetic energy can interfere with
sensitive electronic equipment such as microprocessors, computers, and computer-driven
equipment such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-6. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www.
sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
in Toronto 416-747-4044, website: www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices—phone for Region 5, Chicago, is
312-353-2220, website: www.osha.gov).
1-7. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
OM-4413 Page 4
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT
UTILISATION
rom_10_02fre
Avertissement: Protégez vous et les autres des blessures – lisez et suivez ces précautions.
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés par
des symboles adjacents aux directives.
Identifie un message de sécurité particulier.
Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde !
Soyez vigilant ! Il y a des
risques de danger reliés
aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux
PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-5. Veuillez lire et respecter toutes
ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
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.
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.
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des composants.
OM-4413 Page 5
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
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.
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.
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.
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.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec
précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou
dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
Ne jamais souder une bouteille pressurisée – risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords convenables pour cette application spécifique; les maintenir ainsi
que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
les équipements associés et les publication P-1 CGA énumérées dans les
normes de sécurité.
1-3. Engine Hazards
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-4413 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.
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.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
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.
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
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.
1-4. 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.
1-5. 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-4413 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.
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.
Établir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
Le 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.
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.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
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).
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible
électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que
le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
1-6. 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).
1-7. 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-4413 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 2 – DEFINITIONS
2-1. Symbol Definitions
CC
Stop Engine
Fast
(Run, Weld/Power)
Fast/Slow
(Run/Idle)
Slow (Idle)
Start Engine
Panel/Local
Temperature
Fuel
Engine Oil
High Temperature
Check Valve
Clearance
Battery (Engine)
Engine
Glow Plug
MIG (GMAW),
Wire
Stick (SMAW)
TIG (GTAW)
Circuit Breaker
Constant Voltage
Electrode
Positive
Electrode Negative
Positive
Negative
Alternating Current
(AC)
Output
Time
Hours
Seconds
Protective Earth
(Ground)
Work Connection
Read Operator’s
Manual
CV
Constant Current
h
Do not switch while
welding
14
A
s
Remote 14
Receptacle
Amperes
V
Volts
SECTION 3 – SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
Rated
Welding
Output At
Weld
Speed
Rated
Welding
Output At
Idle Speed
Maximum
Open-Circuit
Voltage
Amperage
Range In
CC Mode
CC/AC
200 A,
25 V, 60%
Duty Cycle
––
75
35 – 250 A
CC/DC
350 A,
28 V, 60%
Duty Cycle
180 A, 28
V, 100%
Duty Cycle
80
20 – 350 A
CV/DC
300 A,
32 V, 100%
Duty Cycle
––
50
––
Voltage
Range In
CV Mode
Generator
Power Rating
Continuous:
Single-Phase,
12 kVA/kW
100/50 A,
120/240 V AC,
60 Hz
Fuel
Capacity
Engine
13 gal (49 L)
Tank
Kubota DH905
Water-Cooled,
Three-Cylinder,
Four-Cycle,
26 HP Diesel
Engine
10 – 34 V
OM-4413 Page 9
3-2. Dimensions, Weights, and Operating Angles
Dimensions
Height
36 in (914 mm)
(to top of exhaust)
Width
24 in (610 mm)
A
B
C
Do not exceed tilt angles or engine could
be damaged or unit could tip.
D
Depth
59-1/2 in (1511 mm)
A
23-5/8 in (600 mm)
B
21-1/2 in (546 mm)
C
1 in (25 mm)
D
15-5/8 in (397 mm)
E
26-3/8 in (679 mm)
F
58-3/4 in (1492 mm)
G
13/32 in (10 mm) Dia.
Do not move or operate unit where it could
tip.
G
4 Holes
E
F
20°
20°
20°
20°
Weight
1030 lb (467 kg)
800 426
Front Panel End
3-3. Fuel Consumption
7.57
2.00
6.62
1.75
DC STICK/AUX POWER
HIGH SPEED
5.67
1.50
4.73
1.25
3.78
1.00
2.84
0.75
DC STICK
(LOW SPEED)
1.98
0.50
0.95
0.25
IDLE
U.S. GAL./HR.
LITERS/HR.
0
0
50
100
150
200
250
300
350
400
DC WELD AMPERES AT 100% DUTY CYCLE
0
1
2
4
6
8 10
12
POWER KVA AT 100% DUTY CYCLE
207 966
OM-4413 Page 10
3-4. 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.
WELD AMPERES
400
350
300
250
200
150
100
0
10
20
30
40
50
60
70
80
90
100
% DUTY CYCLE
60% Duty Cycle at 350 Amperes DC
6 Minutes Welding
4 Minutes Resting
207 959
3-5. AC Generator Power Curve
The ac power curve shows the generator power in amperes available
at the 120 and 240 volt receptacles.
300
AC VOLTS
250
200
150
100
50
0
0
10
20
30
40
50
60
70
80
90
AC AMPERES
207 960
OM-4413 Page 11
3-6. CC Stick Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
A. CC/DC Stick Mode
When
welding in the Stick
mode, the arc drive circuit provides additional amperage during low voltage (short arc
length conditions) to prevent
“sticking” electrodes.
80
DC VOLTS
70
60
50
40
30
20
10
0
0
100
200
300
400
500
600
DC AMPERES
B. CC/AC Stick Mode
80
70
AC VOLTS
60
50
40
30
20
10
0
0
50
100
150
200
250
300
350
AC AMPERES
207 961 / 207 962
OM-4413 Page 12
3-7. CC TIG Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
A. CC/AC TIG Mode
60
AC VOLTS
50
40
30
20
10
0
0
50
100
150
200
250
300
350
AC AMPERES
B. CC/DC TIG Mode
50
DC VOLTS
40
30
20
10
0
0
50
100
150
200
250
300
350
400
450
DC AMPERES
207 964 / 207 965
OM-4413 Page 13
3-8. DC/CV MIG Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
45
40
DC VOLTS
35
30
25
20
15
10
5
0
0
100
200
300
400
500
600
DC AMPERES
207 963
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4413 Page 14
SECTION 4 – INSTALLATION
4-1. Installing Welding Generator
Do not weld on base. Welding
on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.
Movement
Always securely fasten welding generator onto transport
vehicle or trailer and comply
with all DOT and other applicable codes.
Do not lift unit from end.
OR
Do not mount unit by supporting the base only at the four
mounting holes. Use crosssupports to adequately support unit and prevent damage
to base.
Location
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
OR
If unit does not have GFCI receptacles, use GFCI-protected
extension cord.
OR
Mounting:
1
Mounting
Cross-Supports
Mount unit on flat surface or use
cross-supports to support base.
Grounding:
2
3
4
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.
OR
Inadequate support.
Do not use flexible mounts.
1
2
Grounding
3
GND/PE
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
4
Airflow Clearance
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.
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
install2 5/03 – Ref. 800 652 / Ref. 800 477-A / 803 274
OM-4413 Page 15
4-2. Engine Prestart Checks
Remove air bleed screw
when filling radiator. See
Section 4-3.
Check radiator coolant
level when fluid is low in
recovery tank.
Full
Full
Capacity
w/Overflow Tank
6.4 qt (6 L)
Full
1/2 in
(13 mm)
Full
Gauge On
Front Panel
Diesel
803 178
Check all fluids daily. Engine must be cold
and on a level surface. Unit is shipped with
10W30 engine oil.
Engine stops if oil pressure is too low or engine temperature is too high.
This unit has a low oil pressure shut-
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual. If
unburned fuel and oil collect in exhaust pipe
during run-in, see Section 9.
Fuel
Do not use gasoline. Gasoline will
damage engine.
Add fresh diesel fuel before starting engine
the first time (see maintenance label for
specifications). Always leave filler neck
empty to allow room for expansion.
Do not run out of fuel or air enters fuel system and causes starting problems. See engine manual to bleed air from fuel system.
OM-4413 Page 16
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 may use oil and wetstacking
may occur during run-in period.
Check oil several times daily during
run-in.
Coolant
Check coolant level in recovery tank before
starting unit the first time. Add coolant if
coolant is below bottom of radiator filler neck
(see Section 4-3 for radiator filling instructions.
Check coolant in recovery tank daily. If coolant is below Full level, add coolant until coolant level in tank is between Full and Low levels. If recovery tank coolant level was low,
also check coolant level in radiator (see
Section 4-3).
Engine coolant is a mixture of water and
ethylene glycol base antifreeze. A solution
of 50% antifreeze and 50% water must be
used in this engine. Do not use 100% antifreeze or severe damage will occur.
Keep radiator and air intake clean and free
of dirt.
Incorrect engine temperature can
damage engine. Do not run engine
without a properly working thermostat and radiator cap.
To improve cold weather starting:
Use engine block heater (see Section
4-6).
Keep battery in good condition. Store
battery in warm area.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel
information.
Use correct grade oil for cold weather.
See Section 5-5 for additional information
on cold weather operation.
4-3. Adding Coolant To Radiator
Stop engine and let cool.
Check coolant level according
to Section 4-2 before starting
this procedure.
If coolant level is below bottom of
radiator filler neck, add coolant as
follows:
1
1 Radiator Air Bleed Screw
Remove radiator air bleed screw.
Add coolant to radiator until coolant
is at bottom of filler neck. This ensures all air is purged from the system.
Full
Reinstall screw and radiator cap.
Check coolant level in recovery
tank (see Section 4-2).
Capacity
w/Overflow Tank
6.4 qt (6 L)
Engine coolant is a mixture of water
and ethylene glycol base antifreeze. A solution of 50% antifreeze
and 50% water must be used in this
engine. Do not use 100% antifreeze
or severe damage will occur.
Tools Needed:
Ref. 803 178
4-4. Connecting The Battery
Connect
negative (–)
cable last.
–
+
Tools Needed:
3/8, 1/2 in
Ref. 207 554-A / Ref. 803 178 / Ref. S-0756-D
OM-4413 Page 17
4-5. Installing Exhaust Pipe
Point exhaust pipe in desired
direction but always away from
front panel and direction of
travel.
Tools Needed:
1/2 in
802 173-C / Ref. 207 554-A
4-6. Operating Engine Block Heater
Do not run engine while coolant heater is on.
Do not touch hot engine
block. Engine block gets hot
near heater.
1
2
1
Coolant Heater
2
Heater Plug
Use heater to maintain a constant
engine coolant temperature. See
table for heater specifications.
To turn on heater, connect heater
plug to a 120 volt ac grounded receptacle.
To turn off heater, disconnect plug.
Coolant Heater Specifications
Watts
Volts ±10%
Amps
400
120
3.3
Ref. 803 178 / 803 393
OM-4413 Page 18
4-7. Connecting To Weld Output Terminals
Do not connect to CC and CV
terminals at the same time.
1
2
3
Work Weld Output Terminal
CC (Stick/TIG) Weld Output
Terminal
CV (Wire) Weld Output
Terminal
For MIG welding, connect work
cable to Work terminal and wire
feeder cable to CV (Wire) terminal.
For Stick/TIG welding, connect
work cable to Work terminal and
electrode holder cable to CC (Stick/
TIG) terminal.
2
3
1
803 179 / 207 554-A
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4413 Page 19
4-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Stop engine 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)
Do not use worn, damaged, undersized, or
poorly spliced cables.
* This
10 – 100% Duty Cycle
chart is a guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-E–
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
4-9. Remote 14 Receptacle RC4 Information
NOTE
Engine runs at weld/power speed whenever a device connected to the remote 14
receptacle is running.
Socket*
Socket Information
A
24 volts ac. Protected by circuit breaker CB5.
B
Contact closure to A completes 24 volts ac
contactor control circuit.
I
115 volts ac. Protected by circuit breaker CB6.
J
Contact closure to I completes 115 volts ac
contactor control circuit.
C
Output to remote control; 0 to +10 volts dc.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control. Voltage is dependent on front panel Voltage/Amperage control setting.
G
Circuit common for 24 and 115 volts ac circuits.
K
Chassis common.
24 VOLTS AC
A
B
K
J
I
H
C L N
D M
G
E F
115 VOLTS AC
REMOTE
OUTPUT
CONTROL
GND
*The remaining sockets are not used.
OM-4413 Page 20
4-10. Guidelines For Installing Customer-Supplied Emergency Air Shutdown Valve
A customer-supplied emergency air shutdown
valve can be installed to stop the engine immediately in emergency situations.
These guidelines show the typical installation of
a Gator ESD 175-275-L3 air shutdown valve.
Installation of other air shutdown valves may
differ from that shown. Contact the air shutdown valve manufacturer or a Factory Authorized Service Agent for additional installation
and operation information.
Stop engine, and let cool.
Disconnect battery negative (–) cable.
Open doors and remove side panels.
1 Air Cleaner
2 2 in (51 mm) Hose Clamp
3 1-3/4 x 2 in (44 x 51 mm) Rubber Hose
4 Air Shutdown Valve
(Gator ESD 175-275-L3)
5 1-3/4 x 16-1/2 in (44 x 419 mm) Flexible
Radiator Hose (NAPA Part No. FM68)
Use thick-walled rubber hose. Do not use
7
heater hose. (Heater hose could let dirt into
engine.)
6 Engine Air Inlet
7 Shutdown Control
8 42 in (1067 mm) Shutdown Control Cable
(Supplied By Gator)
9 Shutdown Valve Reset Lever
Install components as shown.
Be sure air shutdown valve is installed with air
flow arrow pointing toward air inlet. Use cable
ties to keep air shutdown system components
away from hot or moving parts.
Verify the emergency air shutdown system operates correctly. After testing, use reset lever to
reset air shutdown valve.
Reinstall side panels and close doors.
Reconnect battery negative (–) cable.
1
2
8
3
Mount on lower
front panel
4
9
5
7
6
803 178 / Ref. 803 390
OM-4413 Page 21
SECTION 5 – OPERATING WELDING GENERATOR
5-1. Controls (See Section 5-2)
12
13
14
15
1
2
3
4
5
7
8
6
11
10
9
207 554-A / Ref. 803 178
OM-4413 Page 22
5-2. Description Of Controls (See Section 5-1)
Engine Lights
7
1
Use switch to lock engine in idle or weld/power
speed when Engine Control switch is in the
Speed Lock position. The idle lock switch is
not needed at start-up. The engine always
starts at idle speed.
Engine Temperature Light
Light goes on and engine stops if engine temperature is too high.
Stop engine and fix trouble if Engine
Temperature light goes on.
2
Engine Oil Pressure Light
Light goes on and engine stops if oil pressure
is too low. Light goes on momentarily during
start-up but goes out when engine reaches
normal oil pressure.
Speed Lock Switch
With switch in the Idle position and Engine
Control switch in Speed Lock, the engine runs
at idle speed. With switch in Run position and
Engine Control switch in Speed Lock, engine
runs at weld/power speed.
Stop engine and fix trouble if Engine
Oil Pressure light stays on after startup.
Speed Lock switch does not affect engine
speed when Engine Control switch is in Run/
Idle position. (Engine speed changes with
load.)
3
8
Battery Charging Light
Light goes on if engine alternator is not charging battery. Engine continues to run.
Stop engine and fix trouble if Battery
Charging light goes on.
Engine Gauges
4
Glow Plug Switch
If necessary, push switch down before startup to activate glow plug. See glow plug table
following for operating information.
Do not use glow plugs longer than 20
seconds.
Glow Plug Time
Engine Hour Meter
t
Use meter to schedule maintenance.
Engine Starting Controls
6
Engine Control Switch
Use switch to start engine, select speed, and
stop engine. In Run/Idle position, engine runs
at idle speed at no load, and weld/power
speed under load. In Speed Lock position, engine speed is determined by position of Speed
Lock switch (see item 7 and engine speed
table following).
70°F (21°C)
32°F (0°C)
–4°F (–20°C)
0 seconds
10 seconds
20 seconds
To start:
Do not use ether to start engine.
Using ether voids warranty.
Use glow plug switch if necessary (see item 8
and glow plug table). Turn engine control
switch to Start. Release engine control switch
when engine starts.
The unit will not return to idle speed when
See Section 5-5 for additional information on
cold weather operation.
Process/Contactor switch is in a Wire or
TIG mode and the remote contactor is on
(closure between pins A and B on remote
receptacle).
Engine Control switch does not work (see
item 9).
9 Engine Stop Lever
Use lever to stop engine if Engine Control
switch does not work.
Weld Controls
10 Voltage/Amperage Adjust Switch And
Remote 14 Receptacle
For front panel control, place switch in Panel
position and use the Voltage/Amperage Adjustment control.
For remote control, make connections to Remote 14 receptacle, and place switch in Remote position (see Sections 4-9 and 5-4). The
value selected on Voltage/Amperage Adjustment control is the maximum available at the
remote.
Set Voltage/Amperage Adjustment con-
Use switch to select AC weld output or polarity
of DC weld output.
12 Process/Contactor Switch
See Section 5-3 for Process/Contactor switch
information.
13 Voltage/Amperage Adjustment Control
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage.
With Process/Contactor switch in any MIG
position, use control to adjust voltage.
Place Engine
Control switch in Speed
Lock position and Speed Lock switch in
Run position for TIG (GTAW) welding using a high frequency device.
Push engine stop lever to stop engine if
trol (item13) to max for MIG welding.
11 DC Polarity/AC Selector Switch
Do not switch under load.
Fuel Gauge
Use gauge to check fuel level.
5
To Stop: turn Engine Control switch to Off
position.
If the engine does not start, let the engine
come to a complete stop before attempting restart.
Weld Meters
14 Ammeter (Optional)
Meter displays weld amperage at the weld output terminals.
15 Voltmeter (Optional)
Meter displays weld voltage at the weld terminals, but not necessarily at the welding arc
due to resistance of cables and connections.
Controlling Engine Speed
=
=
Any
position.
=
2525 rpm (Idle Speed)
Continuous
3750 rpm max (Weld/Power Speed)
Continuous.
Use in welding applications where high
speed is needed for better arc starting
and in TIG applications using a high
frequency arc starter.
No Load: 2525 rpm (Idle Speed)
Load: 3750 rpm max (weld/Power
Speed)
OM-4413 Page 23
5-3. Process/Contactor Switch
1
1
Process/Contactor Switch
Weld output terminals are energized when Process/Contactor
switch is in an Electrode Hot position and the engine is running.
The unit will not return to idle speed
when Process/Contactor switch is in
a Wire or TIG mode and the remote
contactor is on (closure between
pins A and B on remote receptacle).
Use switch to select weld process and
weld output on/off control (see table below and Section 5-4).
Place switch in Remote positions to turn
weld output on and off with a device connected to the remote receptacle.
Place switch in Electrode Hot positions
for weld output to be on whenever the engine is running.
Use Stick positions for air carbon arc
(CAC-A) cutting and gouging.
When switch is in a Stick position, the arc
drive circuit provides additional amperage during low voltage (short arc length
conditions) to prevent “sticking” electrodes.
The arc drive circuit is disabled when
switch is in Wire or TIG positions.
207 554-A / 803 179
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Remote – TIG
GTAW With HF Unit, Pulsing Device,
Or Remote Control
At Remote Receptacle
Remote – Stick
Stick (SMAW) With Remote On/Off
At Remote Receptacle
Remote – MIG
MIG (GMAW)
At Remote Receptacle
Electrode Hot – MIG
MIG (GMAW)
Electrode Hot
Electrode Hot – Stick
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting And Gouging
Electrode Hot
Electrode Hot – Scratch
Start TIG
Scratch Start TIG (GTAW)
Electrode Hot
OM-4413 Page 24
5-4. Remote Voltage/Amperage Control
1
Remote 14 Receptacle RC4
Connect optional remote control to
RC4 (see Section 4-9).
1
In Example:
Process = Stick (Using Remote On/Off)
Min = 40 A DC
Max = 180 A DC
Example: Combination Remote Amperage Control (Stick)
Max (180 A DC)
Min (40 A DC)
Set Remote
Process
Set Voltage/
Amperage
Adjust Switch
Set Polarity
Set
Voltage/
Amperage
Control
Adjust Optional Remote Control
0774 / Ref. 207 554-A
In Example:
Process = MIG
Min = 12 V DC
Max = About 42 V DC
Example: Remote Voltage Control (MIG) Using A Voltage-Sensing Wire Feeder
Use this position for
voltage-sensing
feeder
12 V
Set Voltage/
Amperage
Adjust Switch
Set Process
Set Polarity
Voltage/Amperage
Control Not Used
42 V
Adjust Voltage On Feeder
OM-4413 Page 25
5-5. Recommendations For Extreme Cold Weather Operation
For more information on operating in
cold
weather, contact the nearest Factory Authorized Service Agent or Kubota Service
Center.
A 50/50 antifreeze/water mix protects engine to -34° F (–37° C). If operating at even
lower temperatures, contact a Factory
Authorized Service Agent or Kubota Service Center for coolant information.
Operating
To reduce crankcase condensation and
breather tube freezing problems, allow
engine to reach normal operating temperature as quickly as possible.
Crankcase breather tubes will collect
condensation and freeze if the hose is improperly routed. The breather tube should
be free of sharp bends and kinks. A
blocked breather tube will cause excessive crankcase pressure that will blow out
the safety plug, oil seals, or dipstick. Contact a Factory Authorized Service Agent
to obtain a shorter breather hose that is
less likely to kink.
Inspect the routing and condition of the
breather tube frequently. Reroute or replace the hose if necessary.
For continuous use in extreme cold, block
the cooling holes in the base to reduce air
flow through the radiator and achieve
higher engine temperature. Close off the
base inlet vents only if the engine coolant
or oil temperatures can be monitored to
ensure they remain within the specified
limits.
To obtain warmer air for combustion, turn
the air cleaner inlet away from the inlet
vents, and seal the inlet vents.
If operating in cold weather all the time,
consider replacing the existing radiator
cooling fan with a smaller fan that draws
less air through the radiator. Operation in
warmer temperatures would require an
additional “booster” electric fan to adequately cool the engine.
Fuel
Use an arctic-grade diesel fuel and keep
fuel tank at least half full to prevent fuel
lines from draining back into tank.
Do not use gasoline or kerosene.
Do not use fuel additives.
Battery
Replacement Battery Rating: 12 Volt, 535
CCA (minimum) 90 RSV Group 55.
Check connections at battery, starter, and
engine block. Inspect battery cables for
abrasion and wear, and verify the battery
is secured.
Consider installing easily-accessible battery booster leads (0 or 00 AWG) to provide easy connection to a service truck’s
battery.
Oil
Use 10W30 oil when operating at ambient
temperatures above -4° F (–20° C).
Use 5W30 oil when operating at ambient
temperatures above -13° F (–25° C).
Operating at extremely low temperatures
thickens engine oil and reduces cranking
speed. Contact a Factory Authorized Service Agent or Kubota Service Center for
information on using 0W20 oil in these
conditions. Low temperature oil must be
replaced as ambient operating temperatures increase.
Starting
Do not use ether.
Use the engine block heater to maintain
engine temperature above ambient temperature.
Use the glow plugs for 20–30 seconds before starting. As a preseason check,
make sure the glow plugs are working
properly.
Coolant
Be sure the cooling system is completely
filled with a 50/50 antifreeze/water mix
(open the radiator vent when filling). Do
not mix antifreeze and water solution in
the overflow tank. Use a premixed 50/50
antifreeze/water solution to “top off” overflow tank. Use caution if rerouting cooling
lines. Engine damage due to lack of
coolant or incorrect coolant mix is not
covered by the warranty.
Boost the starting capability of the battery
by using a battery heater.
Disconnect all unnecessary loads from
generator ac receptacles when starting.
Notes
Start Your Professional
Welding Career Now!
OM-4413 Page 26
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
Over 80,000 trained
since 1930!
5-6. Typical Stick Welding Connections And Control Settings
Stop engine.
This
section provides general
guidelines and may not suit all
applications.
Typical Settings For
7018 (1/8 in) Electrode
The control panel shows the typi-
cal settings for welding with a
7018 (1/8 in) electrode. Consult
the amperage selection tables
below if welding with other
electrodes.
1 Work Clamp
2 Electrode Holder
Connect Work cable to Work terminal
and Electrode holder cable to CC
(Stick/TIG) terminal on welding generator.
Be sure to use the correct size
weld cables (see Section 4-8).
Typical Settings For 7018 (1/8 in)
Electrode:
>
2
>
1
>
Set Process/Contactor switch to
Electrode Hot – Stick position.
Set DC Polarity/AC Selector
Switch to Electrode Positive
position.
Set amperage (see table
below).
6013
7014
7018
7024
Ni-Cl
308L
USAGE
POSITION
AC
DC*
450
400
350
300
AMPERAGE
RANGE
250
200
150
100
50
ELECTRODE
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
PENETRATION
6010
&
6011
DIAMETER
ELECTRODE
Electrode Selection Tables
6010
EP
ALL
6011
EP
ALL
DEEP MIN. PREP, ROUGH
HIGH SPATTER
DEEP
6013
EP,EN
ALL
LOW
GENERAL
ALL
MED
ALL
LOW
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7014
EP,EN
7018
EP
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
LOW
SMOOTH, EASY,
FASTER
LOW
CAST IRON
LOW
STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Tools Needed:
3/4 in
803 310 / 207 554-A / Ref. S-0653
OM-4413 Page 27
5-7. Typical MIG Welding Connections And Settings
A. Solid Wire Applications
Stop engine.
This section provides general guidelines and may not suit all applications.
Control panel shows
Typical Control Settings For
.035 (ER70S-3)
Solid Wire – Short
Circuit Transfer w/Feeder
Powered By 14-Pin Receptacle
typical settings
for welding with .035 (ER70S-3) solid
wire. Use 75/25 Argon-based shielding
gas.
1 Work Clamp
2 Wire Feeder
3 MIG Gun
4 Gun Trigger Plug
5 14-Pin Plug And Cord
6 Gas Cylinder: 75/25 Argon-Based
Gas for Short Circuit Transfer
7 Gas Hose
Connect work cable to welding generator
Work terminal. Connect cable from feeder
to cable from welding generator CV (Wire)
terminal. Connect feeder 14-pin plug to Remote 14 receptacle on welding generator.
Note Process/Contactor,
Voltage/Amperage, and
DC Polarity/AC Selector
switch settings.
Be sure to use the correct size weld
6
cables (see Section 4-8).
Loosen MIG gun securing knob. Insert gun
end through opening in feeder and position
as close as possible to drive rolls without
touching. Tighten knob.
See wire feeder manual for wire threading
procedure
Insert gun trigger plug (item 4) into matching
receptacle and tighten threaded collar.
Connect gas hose from feeder to regulator
on cylinder.
7
5
Typical Control Settings For Short Circuit Transfer Using .035 (ER70S-3) Solid
Wire And 75/25 Argon-Based Gas w/
Feeder Powered By 14-Pin Receptacle:
>
Quick connector
>
>
2
3
>
>
4
Set Process/Contactor switch to Remote – Wire position.
Set DC Polarity/AC Selector switch to
Electrode Positive position.
Set Output Adjust switch to Remote
position to adjust voltage at feeder.
If feeder does not have remote voltage control, set Output Adjust switch
to Panel and adjust voltage at welding
generator.
Set V/A control to obtain minimum
spatter (typically 17 - 20 volts).
Set wire feed speed between 150-300
ipm.
4
1
Tools Needed:
3/4 in
803 268 / 207 554-A
OM-4413 Page 28
B. Self-Shielded Flux Core Wire Applications
Stop engine.
This
section provides general
guidelines and may not suit all
applications.
Typical Control Settings For 5/64 in. Self-Shielded Flux Core Wire w/Voltage Sensing Feeder
The control panel shows the typi-
cal settings for welding with 5/64
in. self-shielded flux core wire.
1 Work Clamp
2 Wire Feeder
3 MIG Gun
4 Gun Trigger Plug
5 Voltage Sensing Clamp
Connect work cable to welding generator Work terminal. Connect cable
from wire feeder to cable from welding generator CV (Wire) terminal.
Note Process/Contactor,
Voltage/Amperage, and
DC Polarity/AC Selector
switch settings.
Be sure to use the correct size
weld cables (see Section 4-8).
Loosen MIG gun securing knob. Insert gun end through opening in feeder and position as close as possible
to drive rolls without touching. Tighten knob.
See wire feeder manual for wire
threading procedure.
Insert gun trigger plug (item 4) into
matching receptacle and tighten
threaded collar.
Typical Control Settings Using
5/64 in. Self-Shielded Flux Core
Wire w/Voltage Sensing Feeder:
>
Quick connector
>
>
2
3
5
Set Process/Contactor switch
to Electrode Hot – Wire position.
Set DC Polarity/AC Selector
switch to Electrode Negative
position.
Set Output Adjust switch to
Panel and adjust voltage at
welding generator.
Do a test weld. To increase arc
length, increase voltage. To
shorten arc length, reduce voltage or increase wire feed
speed.
4
1
Tools Needed:
3/4 in
803 268 / 207 554-A
OM-4413 Page 29
5-8. Typical MIG Connections And Settings Using Weld Control And Spoolgun
Typical Settings For 4043 (.047)
Aluminum On 1/8 in Material:
Tools Needed:
3/4 in
Note Process/Contactor,
Voltage/Amperage, and
DC Polarity/AC Selector
switch settings.
6
5
8
3
1
7
2
Work
4
803 308 / 207 554-A
Stop engine.
This section
1
2
3
4
5
6
7
8
provides general guidelines and may not suit all applications.
Weld Control
Spoolgun
Weld Power Cable From Spoolgun
Work Clamp
Gas Hose
Argon Cylinder
Trigger Control Cord
14-Pin Plug And Interconnecting Cord
OM-4413 Page 30
Be sure to use the correct size weld
cables (see Section 4-8).
Connect work cable to welding generator
Work terminal. Connect weld cable from
spoolgun to welding generator CV (Wire)
terminal.
Insert trigger control plug (item 7) into weld
control receptacle. Tighten threaded collar.
Insert 14-pin plug (item 8) into 14-pin receptacle on welding generator and tighten
threaded collar.
Connect gas hose from spoolgun to regulator on Argon bottle.
Typical Settings For 4043 (.047)
Aluminum On 1/8 in Material:
>
>
Set Process/Contactor switch to Remote – Wire position.
Set DC Polarity/AC Selector switch to
Electrode Positive position.
Set Output Adjust switch to Panel and
adjust voltage at welding generator
(typically 21 – 28 volts).
5-9. Typical DC Scratch Start TIG Connections And Settings
Typical Settings For 20
Gauge Material:
Tools Needed:
3/4 in
Note Process/Contactor,
Voltage/Amperage, and
DC Polarity/AC Selector
switch settings.
4
5
3
2
1
Work
6
7
803 309 / 207 554-A
Stop engine.
This section
1
2
3
4
5
6
7
provides general guidelines and may not suit all applications.
TIG Torch
Gas Hose
Weld Power Cable
Argon Cylinder
14-Pin Plug And Interconnecting Cord
Remote Control (Foot Or Fingertip)
Work Clamp
Be sure to use the correct size weld
cables (see Section 4-8).
Connect work cable to welding generator
Work terminal. Connect cable from TIG
torch to welding generator CC (Stick/TIG)
terminal.
Insert 14-pin plug (item 5) into 14-pin receptacle on welding generator and tighten
threaded collar.
Connect gas hose from TIG torch to regulator on Argon bottle.
Typical Settings For 20 Gauge Material:
>
>
Set Process/Contactor switch to Electrode Hot – Scratch Start TIG position.
Set DC Polarity/AC Selector switch to
Electrode Negative position.
Set Output Adjust switch to Panel and
adjust amperage at welding generator
(typically 30 – 60 Amps).
OM-4413 Page 31
5-10. Typical AC TIG (With High Frequency Unit) Connections And Settings
Typical Settings For
3/16 in Aluminum
Tools Needed:
3/4 in
Note Process/Contactor,
Voltage/Amperage, and
DC Polarity/AC Selector
switch settings.
5
7
6
4
3
1
2
8
9
803 121 / 207 554-A
Work
11
10
Stop engine.
Turn Off HF Unit and welding power source, and disconnect input
power before making connections.
Stop engine on welding generators.
Not connecting work cables to HF
Unit will damage power source. Always connect work cables to Work
Input/Output terminal.
This section provides general guide-
lines and may not suit all applications.
OM-4413 Page 32
1
2
3
4
5
6
7
8
9
10
11
TIG Torch
Weld Power Cable From TIG Torch
High Frequency (HF) Unit
Gas Hose
Argon Cylinder
Weld Power Cable From HF Unit
14-Pin Plug And Interconnecting Cord
Work Cable To HF Unit
AC Power Cord From HF Unit
Remote Foot Control
Work Clamp From HF Unit
Be sure to use the correct size weld
cables (see Section 4-8).
Connect the work cables from the welding
generator and the work clamp to the HF unit
Work Input/Output terminal. Connect weld
power cable from welding generator CC
(Stick/TIG) terminal to HF unit Electrode-In
Terminal.
Connect torch cable to HF unit ElectrodeOut Terminal.
Connect HF unit ac power cord to welding
generator 120 volt ac receptacle.
Connect remote control cord to receptacle
on HF unit and tighten threaded collar. Connect interconnecting cord to HF unit and Remote 14 receptacle on welding generator.
tighten threaded collar.
Connect gas hose from TIG torch to HF unit
gas valve outlet. Connect gas hose from
cylinder to HF unit gas valve inlet.
Typical Settings For 3/16 in Aluminum:
>
>
>
Set HF unit to Continuous HF and Remote Amperage adjustment.
Set Process/Contactor switch to Remote – TIG position.
Set DC Polarity/AC Selector switch to
AC position.
Set Output Adjust switch to Remote.
Adjust amperage at remote control.
If welding generator amperage setting
is 100 amperes, maximum output
through remote control is 100 amperes.
5-11. Typical Carbon Arc Cutting (CAC-A) Connections And Settings
Typical Settings Using 1/4
in Carbon Electrode:
Tools Needed:
3/4 in
Note Process/Contactor,
Voltage/Amperage, and
DC Polarity/AC Selector
switch settings.
4
3
2
5
1
6
Work
7
803 310 / 207 554-A
Stop engine.
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.
Hot metal from air cutting and gouging can cause fire or explosion. Do
not cut or gouge near flammables.
This section
provides general guidelines and may not suit all applications.
1
2
3
4
5
6
7
Carbon Arc Torch Assembly
Air Hose
Air Valve
Compressed Air Supply Line
(90 PSI at 20 CFM)
Weld Power Cable
Work Cable
Work Clamp
Be sure to use the correct size weld
cables (see Section 4-8).
Connect the work cable to the welding generator Work terminal.
Connect torch assembly weld power cable
to welding generator CC (Stick/TIG) terminal.
Connect torch assembly air hose to compressed air supply valve. Open valve.
>
>
Set Process/Contactor switch to Electrode Hot – Stick position.
Set DC Polarity/AC Selector switch to
Electrode Positive position.
Set Output Adjust switch to Panel and.
adjust amperage at welding generator.
OM-4413 Page 33
SECTION 6 – OPERATING AUXILIARY EQUIPMENT
6-1. Generator Power Receptacles And Circuit Breakers
If unit does not have GFCI
receptacles, use GFCI-protected extension cord.
Generator power decreases as
weld current increases.
1
2
3
1
240 V 50 A AC Receptacle
RC1
RC1 supplies 60 Hz single-phase
power at weld/power speed. Maximum continuous output is 12 kVA/
kW.
2
120 V 20 A AC GFCI Duplex
Receptacle GFCI-2
3
120 V 20 A AC GFCI Duplex
Receptacle GFCI-3
GFCI-2 and GFCI-3 supply 60 Hz
single-phase power at weld/power
speed. Maximum output from
GFCI-2 or GFCI-3 is 2.4 kVA/kW.
4
4
Circuit Breaker CB1
CB1 protects RC1, GFCI-2, GFCI-3
from overload. If CB1 opens, the receptacles do not work.
5
Circuit Breaker CB3
6
Circuit Breaker CB4
CB3 protects GFCI-2 and CB4 protects GFCI-3 from overload. If a circuit breaker opens, the receptacle
does not work.
Move switch (CB1) or press but-
ton (CB3, CB4) to reset circuit
breaker. If breaker continues to
open, contact Factory Authorized Service Agent.
5
6
Simultaneous Welding And Genertor Power Output
Weld Current
Amperes
0
100
150
200
300
350
Watts
12000
11000
9500
7500
3000
1000
120 V
Receptacle
Amperes
240 V
Receptacle
Amperes
100
90
80
62
25
10
50
45
40
31
12
5
Combined output of all receptacles
limited to 12 kVA/kW rating of the
generator.
EXAMPLE: If 20 A is drawn from
each 120 V duplex receptacle, only
30 A is available at the 240 V
receptacle:
2 x (120 V x 20 A) + (240 V x 30 A) =
12 kVA/kW
Ref. ST-207 554-A
OM-4413 Page 34
6-2. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
1
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
3
4
1
Tools Needed:
Plug Wired for 120/240 V,
3-Wire Load
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
120V
120V
5
240V
6
2
3
4
2
Plug Wired for 240 V, 2-Wire
Load
3
Neutral (Silver) Terminal
4
Load 1 (Brass)Terminal
5
Load 2 (Brass) Terminal
6
Ground (Green) Terminal
Strip cord jacket back enough to
separate conductors.
Strip conductors enough to make
good contact with plug terminals.
Make plug connections and reinstall outer shell and cord grip.
240V
6
5
Tighten assembly screws onto
shell. Do not overtighten.
Plug1 7/99 – ST-120 813-D
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING
7-1. Maintenance Label
OM-4413 Page 35
7-2. Routine Maintenance
Note
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Stop engine before performing maintenance.
Recycle
engine
fluids.
See also Engine Manual and Maintenance Label.
Service engine more often if used in severe conditions.
*
To be done by Factory Authorized Service Agent.
Every 8 h
Full
Check Fluid
Levels. See
Section 4-2.
Wipe Up
Spills.
Drain Water From
Fuel System. See
Section 7-5.
Recovery Tank
Every 20 h
Check and clean optional
spark arrestor screen.
See Section 7-3.
Every 50 h
Clean and
tighten weld
terminals.
Check fuel lines
and
connections.
See Section 7-5.
Every 100 h
Check air cleaner hoses
for cracks and loose
clamps.
Service air filter element.
See Section 7-4.
Clean and
tighten battery
connections.
5/16 in.
(8 mm)
Check belt tension.
Every 200 h
Change oil filter.
Section
7-5
maintenance label.
Change oil. See Section 7-5
and maintenance label.
Replace primary
(in-line) fuel filter.
See Section 7-5.
Check radiator
hoses
and
clamps.
Replace unreadable
labels.
Every 400 h
Replace secondary
fuel filter. See
Section 7-5.
OM-4413 Page 36
See
and
FUEL
WATER
Every 500 h
Replace fan belt.
Drain sludge from
fuel tank. See
Section 7-5.
Flush radiator.
FUEL
SLUDGE
Repair or replace
cracked cables.
Every 800 h
Check valve
clearance.*
Every 1000 h
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
OR
Service welding generator
brushes and slip rings. Service
more often in dirty conditions.*
Every 2000 h
Replace fuel
lines
and
clamps. See
Section 7-5.
Replace
radiator
coolant and hoses.
See Section 7-6.
7-3. Servicing Optional Spark Arrestor
Stop engine and let cool.
1
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
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.
Stop engine and let cool.
Reinstall cleanout plug.
1
Tools Needed:
1/4 in
802 656
OM-4413 Page 37
7-4. Servicing Air Cleaner
Stop engine.
Do not run engine without air
cleaner or with dirty element. Engine damage caused by using a
damaged element is not covered
by the warranty.
The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
1
2
4
3
5
6
7
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.
1
2
3
4
8
Intake Manifold
Service Indicator
Window
Reset Button
Service air cleaner element if red band
appears in window. A clear window
means air cleaner is okay. Press button to
reset indicator.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
Optional
9
5
Housing
6
Safety Element (Optional)
7
Primary Element
8
Dust Cap
9
Dust Ejector
To clean air filter:
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
Keep nozzle
2 in (51 mm)
from element.
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.
Blow
Inspect
Reinstall primary element and cap (dust
ejector down).
aircleaner1 5/02 – ST-153 929-B / ST-153 585 / Ref. 803 283 / Ref. S-0698-B
OM-4413 Page 38
7-5. Servicing Engine Lubrication And Fuel Systems
3
FLOW
4
3
5
7
1
6
Tools Needed:
2
9/16 in
Ref. 803 178 / Ref. 207 554-A / S-0842
Stop engine and let cool.
Close valve and valve cap before adding oil and running engine.
1
Oil Filter
2
3
4
Oil Drain Valve
Fuel Line
Primary (In-Line) Fuel Filter
Fill crankcase with new oil to full mark on
dipstick (see Section 4-2).
5
Secondary (Canister) Fuel Filter
6
Petcock
Open secondary fuel filter petcock and
drain water into metal container. Close petcock when water-free fuel flows.
7
Fuel Tank Sludge Drain Valve
To change oil and filter:
Pull oil drain hose through access hole in
base. Change engine oil and filter according to instructions in engine manual.
Replace fuel lines if cracked or worn.
Wipe up any spilled fuel.
After servicing, start engine and
check for fuel leaks.
To drain water from fuel system:
To change fuel filters:
Install new primary fuel filter as shown.
Replace secondary fuel filter according to
engine manual.
Stop engine, tighten connections as
necessary, and wipe up fuel.
To drain sludge from fuel tank:
Attach hose to drain valve. Put metal container under drain. Open valve and drain
sludge by turning valve screw counterclockwise. Close valve and remove hose
when done.
OM-4413 Page 39
7-6. Servicing Engine Cooling System
Stop engine and let cool.
1
Radiator Draincock
2
Radiator Cap
3
Radiator Air Bleed Screw
Change coolant according to engine
manual. Add coolant according to Section 4-3).
Run engine until engine reaches normal
operating temperature. Loosen air bleed
screw to remove air from cooling system.
Tighten screw.
Check coolant level in recovery tank. Add
coolant if necessary
1
3
2
802 579-B / 803 178 / 802 581
OM-4413 Page 40
7-7. Replacing Throttle Solenoid TS1
Stop engine, and let cool.
Disconnect battery, negative
(–) cable first.
Remove right side engine panel.
1
2
3
4
5
6
7
Plug PLG39/Receptacle
RC39
Throttle Solenoid TS1
Shoulder Bolt And Nut
Throttle Link
Throttle Solenoid Plunger Rod
Jam Nut
Throttle Arm
Disconnect solenoid plug PLG39
from wiring harness receptacle
RC39.
Remove shoulder bolt and nut from
throttle link.
Remove solenoid from mounting
bracket.
Note how much thread is visible on
solenoid plunger rod. Loosen jam
nut just enough so throttle link can
be removed from solenoid rod.
Install throttle link on new solenoid
plunger rod. Turn link until the same
amount of thread will be visible on
plunger rod when the jam nut is
tightened. (Do not tighten jam nut
yet.)
Mount solenoid on bracket. Move
solenoid plunger manually to align
slot in throttle link with hole in
throttle arm. Insert shoulder bolt
through slot/hole and secure with
nut.
1
Be sure solenoid plunger rod
pulls all the way in “bottoms”
when energized. If plunger rod
does not pull all the way in, readjust throttle link.
2
7
Tighten jam nut on solenoid plunger
rod. Verify all other hardware is
tight.
Connect solenoid plug PLG39 to
wiring harness receptacle RC39.
Reconnect battery, negative (–)
lead last.
Check engine speeds and adjust if
necessary according to Section
7-8.
Reinstall side panel.
Tools Needed:
5
6
4
3
7/16, 3/8, 1/2 in
10 mm
3/16 in
803 178
OM-4413 Page 41
7-8. Adjusting Engine Speed
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
2500 rpm
Start engine and run until warm.
Turn Voltage/Amperage control to
max.
3750 Max
Adjusting Idle Speed
Turn Engine Control switch to Run/
Idle position.
1
2
3
Throttle Solenoid
Idle Speed Jam Nut
Idle Speed Screw
Loosen nut and turn screw clockwise to increase idle speed. Turn
screw counterclockwise to decrease idle speed. Tighten nut.
See engine manual for governor
sensitivity adjustment.
Adjusting Weld/Power Speed
4
5
Weld Speed Jam Nut
Adjustment Screw
Turn Engine Control switch to Run
position. Loosen nut and turn screw
counterclockwise to increase
speed. Turn screw clockwise to decrease speed. Tighten nut.
Using Engine Stop Lever
6
Engine Stop Lever
Use lever to stop engine if Engine
Control switch does not work.
4
5
3
2
1
6
Tools Needed:
10 mm
803 178
OM-4413 Page 42
7-9. Overload Protection
Stop engine.
Tools Needed:
3/8 in
When a circuit breaker opens,
it usually indicates a more serious problem exists. Contact
Factory Authorized Service
Agent.
1 Circuit Breaker CB5
CB5 protects the 24 volt ac output
to Remote 14 receptacle RC4. If
CB5 opens, 24 volt ac output to
RC4 stops.
2 Circuit Breaker CB6
CB6 protects the 115 volt ac output
to Remote 14 receptacle RC4. If
CB6 opens, 115 volt ac output to
RC4 stops.
Press button to reset breaker.
3 Circuit Breaker CB7
4 Circuit Breaker CB8
5 Circuit Breaker CB10
1
CB7 protects the engine glow plug
from overload. If CB7 opens, the
glow plug does not work and engine
may not start in cold weather.
Check continuity and connections
of engine glow plug.
2
CB8 protects the engine wiring system from overload. If CB8 opens,
the engine will not crank. Check
battery, starter, and engine control
switch.
6
CB10 protects the engine fuel solenoid from overload. If CB10 opens,
the engine cranks but does not
start. Check fuel solenoid FS1 for
obstructions.
6
5
4
3
Fuse F1 (On Power Board
PC7)
F1 protects the exciter excitation
winding from overload. If F1 opens,
generator power output stops or is
low. Weld output is still available.
Replace any open fuses. Reinstall
cover before operating unit.
803 178 / 803 180
OM-4413 Page 43
7-10. Troubleshooting
A. Welding
Trouble
Remedy
No weld output; generator power output Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and
okay at ac receptacles.
connect remote contactor to optional Remote 14 receptacle RC4 (see Section 4-9).
Check position of DC Polarity/AC switch.
Reset circuit breaker(s) CB5 and CB6 (see Section 7-9). Check for faulty remote device connected to
RC4.
Check and secure connections to Remote 14 receptacle RC4 (see Section C).
Have Factory Authorized Service Agent check capacitor board PC4 and connections.
Have Factory Authorized Service Agent check brushes and slip rings, field excitation circuit, circuit
boards PC1 and PC2, and the rotor.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Check fuse F1, and replace if open (see Section 7-9).
Have Factory Authorized Service Agent check brushes and slip rings, field excitation circuit, circuit
boards PC1 and PC7, and the rotor.
Erratic weld output.
Check control settings.
Clean and tighten connections both inside and outside unit.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Use dry, properly stored electrodes.
Check and adjust engine speed (see Section 7-8).
Check and secure lead connections to remote A/V control.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
High weld output.
Check position of Voltage/Amperage Adjust control.
Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent check circuit boards PC1 and PC2.
Low weld output.
Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent check brushes and slip rings, field excitation circuit, circuit
boards PC1 and PC2, and the rotor.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
Weld output cannot be adjusted.
Check position of Voltage/Amperage Adjust switch (see Section 5-1).
No power output at Remote 14 receptacle RC4.
Reset circuit breaker CB5 and/or CB6 (see Section 6-1).
No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position.
control.
Check and secure connections to Remote 14 receptacle RC4 (see Section 4-9).
Repair or replace remote control device.
OM-4413 Page 44
Trouble
Min or max CV weld output only.
Remedy
Check position of Voltage/Amperage Adjustment control and Voltage/Amperage Adjust switch (see Section 5-1).
Repair or replace remote control device.
Have Factory Authorized Service Agent check circuit boards PC1 and PC2.
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Welding arc.
Use proper size tungsten for welding amperage.
Operate unit at weld/power speed.
Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Wandering arc – poor control of arc
direction.
Reduce gas flow rate.
Select proper size tungsten. Properly prepare tungsten.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
B. Generator Power
Trouble
No generator power output at ac receptacles; weld output okay.
Remedy
Reset circuit breakers CB1, CB3 and/or CB4 (see Section 6-1).
Check fuse F1, and replace if necessary (see Section 7-9).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC7.
No generator power at ac receptacles
or weld output.
Disconnect equipment from generator power ac receptacles during start-up.
Check fuse F1, and replace if necessary (see Section 7-9).
Have Factory Authorized Service Agent check brushes and slip rings, field excitation circuit, circuit
boards PC1 and PC7, and the rotor.
Low power output at ac receptacles.
Check and clean air cleaner as necessary (see Section 7-4).
Check engine speed, and adjust if necessary (see Section 7-8).
Have Factory Authorized Service Agent check circuit boards PC1 and PC7.
See engine manual.
High power output at ac receptacles.
Check engine speed, and adjust if necessary (see Section 7-8).
Have Factory Authorized Service Agent check circuit boards PC1 and PC7.
Erratic power output at ac receptacles.
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC7.
Check receptacle wiring and connections.
Check governor according to engine manual.
OM-4413 Page 45
C. Engine
Trouble
Engine will not crank.
Remedy
Reset circuit breaker CB8 (see Section 7-9).
Check battery voltage.
Check battery connections and tighten if necessary.
Have Factory Authorized Service Agent check Engine Control switch S2.
Engine cranks, but does not start.
Check fuel level (see Section 4-2).
Check oil level (see Section 4-2). Engine will not start if oil pressure is low.
Reset circuit breaker CB10 (see Section 7-9).
Check coolant level and fan belt (see Section 4-2 and engine manual). Engine will not start if coolant
temperature is high.
Use Glow Plug if unit does not start in cold weather. If unit still does not start, reset circuit breaker
CB7 (see Section 7-9).
Service primary and secondary fuel filters (see Section 7-5).
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Bleed air from fuel system according to engine manual.
Have Factory Authorized Service Agent check low oil pressure switch S5, engine coolant temperature switch S4, and control relay CR1.
See engine manual.
Engine starts but stops when Engine
Control switch is released.
Check oil level (see Section 4-2). Engine will not start if oil pressure is too low.
Reset circuit breaker CB10 (see Section 7-9).
Check coolant level and fan belt (see Section 4-2 and engine manual). Engine will not start if engine
temperature is too high.
Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see engine manual).
Have Factory Authorized Service Agent check low oil pressure switch S5 and engine coolant temperature switch S4.
Engine does not stop.
Stop engine by pushing down engine stop lever (see Section 7-8). After stopping engine, adjust fuel
solenoid linkage (see engine manual).
Engine stopped during normal
operation.
Check fuel level (see Section 4-2).
Open fuel valve (see Section 4-2).
Check oil level (see Section 4-2). Engine stops if oil pressure is too low.
Check coolant level and fan belt (see Section 4-2 and engine manual). Engine stops if engine temperature is too high.
Bleed air from fuel system according to engine manual.
Have Factory Authorized Service Agent check low oil pressure switch S5 and engine coolant temperature switch S4.
Battery discharges between uses.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator according to engine manual.
OM-4413 Page 46
Trouble
Engine does not return to idle speed
when load is removed with Engine
Control switch in Run/Idle position.
Remedy
Remove all weld and generator power loads.
Place Process/Contactor switch in Electrode Hot position or turn off remote contactor. The unit will not
return to idle speed when Process/Contactor switch is in a remote position and the remote contactor
is on.
Turn off remote device connected to Remote 14 receptacle RC4 (see Section 4-9).
Check for obstructed movement of throttle solenoid linkage.
Have Factory Authorized Service Agent check control relay CR2, current transformer CT1, throttle
solenoid TS1, and circuit boards PC1 and PC2.
Engine does not remain at weld/power
speed when power or weld load is
applied with Engine Control switch in
Run/Idle position.
Check for obstructed movement of solenoid linkage (see Section 7-8).
Have Factory Authorized Service Agent check control relay CR2, current transformer CT1, throttle
solenoid TS1, and circuit boards PC1 and PC2.
Engine does not remain at idle speed
with Engine Control switch in Speed
Lock position and Speed Lock switch
in Idle position.
Check for obstructed movement of solenoid linkage (see Section 7-8).
Have Factory Authorized Service Agent check control relay CR2, Idle Lock switch S7, throttle solenoid TS1, and circuit boards PC1 and PC2
Engine does not remain at weld/power
speed with Engine Control switch in
Speed Lock position and Speed Lock
switch in Run position.
Check for obstructed movement of solenoid linkage (see Section 7-8).
Have Factory Authorized Service Agent check control relay CR2, Idle Lock switch S7, throttle solenoid TS1, and circuit boards PC1 and PC2.
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine (see Section 9 and engine manual).
Coolant recovery tank continuously
overflows.
Bleed air from radiator, and replace lost coolant (see Section 4-3).
OM-4413 Page 47
SECTION 8 – ELECTRICAL DIAGRAMS
Figure 8-1. Circuit Diagram For Welding Generator
OM-4413 Page 48
208 872-A
OM-4413 Page 49
SECTION 9 – RUN-IN PROCEDURE
run_in4 8/01
9-1. Wetstacking
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
2
1
Welding Generator
Run diesel engines near rated voltage and current during run-in period
to properly seat piston rings and
prevent wetstacking. See nameplate, rating label, or specifications
section in this manual to find rated
voltage and current.
1
2
Do not idle engine longer than
necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generator is kept loaded during
run-in.
Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional engine run-in information.
OM-4413 Page 50
9-2. Run-In Procedure Using Load Bank
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Keep exhaust and pipe away
from flammables.
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
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe
correct
polarity.
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator V/A control so load
equals 225 amps at 30 volts.
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
3
Check oil level frequently during run-in; add oil if needed.
After one hour (minimum) place V/A
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-4413 Page 51
9-3. Run-In Procedure Using Resistance Grid
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Keep exhaust and pipe away
from flammables.
6
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
2
1 Resistance Grid
Use grid sized for generator rated
output.
1
Turn Off grid.
2
Welding Generator
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connectors (polarity is not important).
4
Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several
minutes.
3
5
Set grid switches and then adjust
generator V/A control so load
equals 225 amps at 30 volts.
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
Check oil level frequently dur-
4
ing run-in; add oil if needed.
+
After one hour (minimum), place
V/A 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-4413 Page 52
SECTION 10 – 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.
10-1. Selecting Equipment
1
2
3
Generator Power Receptacles
– Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
Do not use 2-prong plug unless equipment is double insulated.
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 11/02 – Ref. ST-159 730 / ST-800 577
10-2. 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, an 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-4413 Page 53
10-3. Grounding When Supplying Building Systems
1
1
2
Equipment Grounding
Terminal
Grounding Cable
2
GND/PE
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Use ground device as stated
in electrical codes.
2
3
ST-800 576-B
10-4. How Much Power Does Equipment Require?
1
3
2
1
VOLTS 115
AMPS 4.5
Hz
60
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
Non-Resistive Load
Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running
(see Section 10-8).
3
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
AMPERES x VOLTS = WATTS
EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-4413 Page 54
10-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
10-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
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-4413 Page 55
10-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
OM-4413 Page 56
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
10-8. Power Required To Start Motor
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
1
2
3
4
2
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welding generator amperage output must be at least twice the
motor’s running amperage.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230
HP = 1/4
Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A Starting the motor requires 12.2 amperes.
230
S-0624
10-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-4413 Page 57
10-10. Typical Connections To Supply Standby Power
Properly install and ground this equipment according to
its Owner’s Manual and national, state, and local codes.
1
2
Utility
Electrical
Service
3
Transfer Switch
4
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
5
Essential
Loads
Have only qualified persons perform
these connections according to all
applicable codes and safety practices.
Switch transfers the electrical load from
electric utility service to the generator. Transfer load back to electric utility when service is
restored.
Properly install and ground this
equipment according to its Owner’s
Manual and national, state, and local
codes.
Install correct switch (customer-supplied).
Switch rating must be same as or greater
than the branch overcurrent protection.
Customer-supplied
equipment is required if generator will supply standby
power during emergencies or power outages.
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
3 Fused Disconnect Switch
Install correct switch (customer-supplied) if
required by electrical code.
4 Welding Generator Output
Generator output voltage and wiring must be
consistent with regular (utility) system voltage and wiring.
Connect generator with temporary or permanent wiring suitable for the installation.
Turn off or unplug all equipment connected to
generator before starting or stopping engine.
When starting or stopping, the engine has
low speed which causes low voltage and
frequency.
5 Essential Loads
Generator output may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
requirements, connect only essential loads
(pumps, freezers, heaters, etc. – See Section 10-4).
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4413 Page 58
10-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
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-4413 Page 59
SECTION 11 – PARTS LIST
Hardware is common and
not available unless listed.
17
18
15
7
16
14
6
13
12
11
10
9
8
19
5
4
20
21
3
30
29
22 – Fig.11-3
31
28
32
104
33
2
34
1
105
103 Fig. 11-2
35
23
24
27
26
25
99
100
102
101
Figure 11-1. Main Assembly
OM-4413 Page 60
63
62
61
60
64
59
58
65
57
54
56
55
38
106
40
37
36 – Fig. 11-4
66
67
52
68
39
72
70
53
69
71
51
73
50
47
44
77
41
74
75
42
49
46
95
43
48
76
45
93
78
80
94
92
81
91
79
90
82
85
83
84
86
89
87
88
98
97
96
803 269
OM-4413 Page 61
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . 013367
. . . 2 . . . . . . . . . . . . . +198157
. . . 2 . . . . . . . . . . . ♦+198 873
. . . 3 . . . . . . . . . . . . . . 200795
. . . 4 . . . . . . . . . . . . . +198155
. . . 4 . . . . . . . . . . . +♦198 871
. . . . . . . . . . . . . . . . . . ♦163175
. . . . . . . . . . . . . . . . . . ♦163167
. . . . . . . . . . . . . . . . . . ♦163174
. . . . . . . . . . . . . . . . . . . . 173348
. . . 5 . . . . . . . . . . . . . . 192041
. . . 6 . . . . . . . . . . . . . . 200775
. . . 7 . . . . . . . . . . . . . . 198159
. . . 8 . . . . . . . . . . . . . . 193411
. . . 9 . . . . . . . . . . . . . . 198156
. . . 9 . . . . . . . . . . . . ♦198872
. . . 10 . . . . . . . . . . . . . . 198525
. . . 11 . . . . . . . . . . . . . . 198164
. . . 11 . . . . . . . . . . . +♦198 878
. . . 12 . . . . . . . . . . . . . . 194320
. . . 13 . . . . . . . . . . . . . . 194295
. . . 14 . . . . . . . . . . . . . +198162
. . . 14 . . . . . . . . . . . . ♦198 875
. . . 15 . . . . . . . . . . . . . . 200448
. . . 16 . . . . . . . . . . . . . . 183314
. . . 17 . . . . . . . . . . . . . . 201882
. . . 18 . . . . . . . . . . . . . . 198153
. . . 19 . . . . . . . . . . . . . . 176230
. . . 20 . . . . . . . . . . . . . . 194320
. . . 21 . . . . . . . . . . . . . +198154
. . . 21 . . . . . . . . . . . . ♦198 870
. . . 22 . . . . . . . . . . . Figure 11-3
. . . 23 . . . . . . . . . . . . . . 198167
. . . 24 . . . . . . . . . . . . . . 190861
. . . . . . . . . . . . . . . . . . . . 208871
. . . . . . . . . . RC5 . . . . 158466
. . . . . . . . . PLG38 . . . 192170
. . . . . . . . . . . . . . . . . . . . 192169
. . . . . . . . . PLG36 . . . 192171
. . . . . . . . . PLG37 . . . 192168
. . . . . . . . . PLG39 . . . 092670
. . . . . . . . . . . . . . . . . . . . 192167
. . . 25 . . . . CB10 . . . . 139266
. . . 26 . . . . CB8 . . . . 115427
. . . 27 . . . . CB7 . . . . 147658
. . . . . . . . . . . . . . . . . . . . 187654
. . . 28 . . . . . . . . . . . . . . 198054
. . . . . . . . . . . . . . . . . . . . 209344
. . . 29 . . . . CR3 . . . . 155309
. . . 30 . . . . . . . . . . . . . . 193414
. . . 31 . . . . . . . . . . . . . . 172296
. . . 32 . . . . . . . . . . . . . . 192239
. . . 33 . . . . . . . . . . . . . . 206795
. . . 34 . . . . . . . . . . . . . +197265
. . . 35 . . . . . . . . . . . . . . 203260
. . . 36 . . . . . . . . . . . Figure 11-4
. . . 37 . . . . . S5 . . . . . 197145
. . . 38 . . . . . . . . . . . . . . 192517
OM-4413 Page 62
. . Label, Warning Moving Parts Can Cause Serious Etc . . . . . . . . . . . . . . . . 1
. . Panel, Generator Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Generator Left Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning General Precautionary Csa . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Generator Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, 250–20x .75 Hex Hd–pln Stainless Pln T18–8 302–305 . . . . . . . . 37
. . Washer, Lock .254idx0.489odx.062t Stainless Split.250 . . . . . . . . . . . . . . . 37
. . Washer, Flat .281idx0.625odx.050t Stainless . . . . . . . . . . . . . . . . . . . . . . . . 37
. . Extrusion, Rubber W/Adhesive .370 X .750 . . . . . . . . . . . . . . . . . . . . . . . 4.75 ft
. . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Edge, Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ft
. . Tray, Fuel Spill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Brace, Hood Access Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Access Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hinge, Door Access 180 Deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Hood, Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hood, Access Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Latch, Lever Flush Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Diesel Engine Maintenance Kubota 905/1005 . . . . . . . . . . . . . . . . . 1
. . Plenum, Radiator Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Plenum, Radiator Cover Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Steam And Hot Coolant Can Burn . . . . . . . . . . . . . . . . . . . 1
. . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Pipe, Exhaust Elbow 1.654 ID Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Latch, Lever Flush Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Door, Access Removable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Door, Access Removable Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Stabilizer/Rectifier/Control box Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Support, Weld Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Label, Warning Electric Shock And Moving Parts Etc . . . . . . . . . . . . . . . . 1
. . Harness, Wrg Engine Compartment (consisting of) . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . 1
. . . . Conn, Rect 250 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect 250 1skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect 250 3skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect 250 1pin 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . Seal, Wire Univ 3p/S 1row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . . Circuit Breaker, Man Reset 1p 25a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . . Circuit Breaker, Man Reset 1p 30a 250vac Screw . . . . . . . . . . . . . . . . . 1
. . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Upright, Base Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Seal, Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Contactor, Solenoid 12vdc Continuous 400a Inrush . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Gas Spring Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ball Gas Spring, Stud .39 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Spring, Pressure Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Switch, Pressure Oil 7psi Nc Screw Term . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Gasket, Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (Continued)
. . . 39 . . . . . . . . . . . . . . 193624
. . . 40 . . . . . S4 . . . . . 205800
. . . 41 . . . . . . . . . . . . . . 192475
. . . 42 . . . . . . . . . . . . . . 118829
. . . 43 . . . . . . . . . . . . . . 194127
. . . 44 . . . . . . . . . . . . . . 145675
. . . 45 . . . . TS1 . . . . 192196
. . . 46 . . . . . . . . . . . . . . 192663
. . . 47 . . . . . . . . . . . . . . 047235
. . . 48 . . . . . . . . . . . . . . 047234
. . . 49 . . . . . . . . . . . . . . 203897
. . . 50 . . . . . . . . . . . . . . 165271
. . . 51 . . . . . . . . . . . . . +187462
. . . 52 . . . . . . . . . . . . . . 192934
. . . . . . . . . . . . . . . . . . . . 192517
. . . . . . . . GLOW PLUG . 187820
. . . . . . . . . . . . . . . . . . . . 206107
. . . . . . . . . . . . . . . . . . . *197197
. . . . . . . . . . . . . . . . . . . . 010146
. . . 53 . . . . . . . . . . . . . . 197671
. . . 54 . . . . . . . . . . . . . . 192194
. . . 55 . . . . . . . . . . . . . . 197146
. . . 56 . . . . . . . . . . . . . . 191693
. . . 57 . . . . . . . . . . . . . +202243
. . . 58 . . . . . . . . . . . . . . 191341
. . . 59 . . . . . . . . . . . . . . 198186
. . . 60 . . . . . . . . . . . . . . 197822
. . . . . . . . . . . . . . . . . . . . 187120
. . . 61 . . . . . . . . . . . . . . 194578
. . . 62 . . . . . . . . . . . . . . 198181
. . . 63 . . . . . . . . . . . . . . 191626
. . . 64 . . . . . . . . . . . . . . 192195
. . . 65 . . . . . . . . . . . . . . 182092
. . . 66 . . . . . . . . . . . . . . 201528
. . . 67 . . . . . . . . . . . . . . 198187
. . . 68 . . . . . . . . . . . . . . 198185
. . . 69 . . . . . . . . . . . . . . 191342
. . . 70 . . . . . . . . . . . . . . 202198
. . . 71 . . . . . . . . . . . . . *192744
. . . 72 . . . . . . . . . . . . . *066113
. . . 73 . . . . . . . . . . . . . *196428
. . . 74 . . . . . . . . . . . . . . 192476
. . . 75 . . . . . . . . . . . . . . 192188
. . . . . . . . . . . . . . . . . . . *187441
. . . . . . . . . . . . . . . . . . . *202102
. . . 76 . . . . . . . . . . . . . . 193026
. . . 77 . . . . . . . . . . . . . . 209329
. . . 78 . . . . . . . . . . . . . . 197256
. . . 79 . . . . . . . . . . . . . . 197227
. . . 80 . . . . . . . . . . . . . . 110465
. . . 81 . . . . . . . . . . . . . . 032453
. . . 82 . . . . . . . . . . . . . . 204875
. . . 83 . . . . BATT . . . . 146237
. . . . . . . . . . . . . . . . . . . . 108081
. . . 84 . . . . . . . . . . . . . . 114923
. . . 85 . . . . . . . . . . . . . . 182276
. . . 86 . . . . . . . . . . . . . . 494604
. . . 87 . . . . . . . . . . . . . . 097829
. . Engine, Kubota Dsl Elec Dh905–mi–b (Consisting Of) . . . . . . . . . . . . . . . . 1
. . . . Switch, Thermo Temp 230deg +/–5deg F No . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Support, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Screw, shld stl sch .312-18 x .500 x .375 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Linkage, Throttle Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Nut, .312-18 .50 hex .37h stl Pld Deformed Lkg thrd . . . . . . . . . . . . . . . . 1
. . . . Solenoid, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bracket, Mtg Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Washer, Seal Oil Copper .879id X 1.059od 111–8737 . . . . . . . . . . . . . . 2
. . . . Banjo Bolt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Hose, Oil W/Fittings 22.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Valve, Oil Drain 3/8–18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bottle, Overflow W/Cap & Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bracket, Mtg Coolant Recovery Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Gasket, Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Injector Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Belt, Fan Kubota 905 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Clamp, Nyl .625 Clamp Dia X.500 Wide (For Overflow Bottle Hose) . . . 1
. . Label, Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pipe, Exhaust Flexible Inlet W/Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Fan, Engine 330mm Pusher Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Radiator Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Radiator Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Radiator, W/14# Cap 3 Row Core 1.125 Inlet/Outlet . . . . . . . . . . . . . . . . . 1
. . Cap, radiator pressure 14 lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Baffle, Foam Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Radiator Arch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Pipe, Exhaust Outlet 1.625 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Moving Parts Can Cause Serious Etc . . . . . . . . . . . . . . . . 1
. . Muffler, Exhaust Engine Kubota Dh905 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Radiator Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Baffle, Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Radiator Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Base, Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Filter, Fuel Spin–on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Filter, Fuel Inline .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Filter, Oil Kubota 905dh/1005dh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Mount, Engine Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Air Cleaner, Intake 90deg Outlet 4.25in Dia. . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Band, Mtg Air Cleaner Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Indicator, restriction air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Elbow Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Elbow Air Cleaner 1.750id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Tubing, Corrugated Plastic Slit .500 dia x coil . . . . . . . . . . . . . . . . . . . . . . . 2.1 ft
. . Cable, Bat Neg 26.000 No.2 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . . 1
. . Hold Down, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Battery, Stor 12v 535 Crk 90 Rsv Gp 55 Maint Free . . . . . . . . . . . . . . . . . 1
. . Terminal Protector, Battery Post Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Boot, Insulator Term Post Red 1/0 Cable .875odx1.00 . . . . . . . . . . . . . . . 2
. . Cable, Bat Pos 28.000 No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . . 1
. . Bolt, J Stl .250–20 X 8.000 Pld W/Nuts&washers . . . . . . . . . . . . . . . . . . . . 2
. . Bolt, J Stl .250–20 X 2.750 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4413 Page 63
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (Continued)
. . . 88 . . . . . . . . . . . . . . 200407
. . . 89 . . . . . . . . . . . . . . 198168
. . . 90 . . . . . . . . . . . . . . 198180
. . . 91 . . . . . . . . . . . . . . 181572
. . . 92 . . . . . . . . . . . . . . 198510
. . . 93 . . . . . . . . . . . . . . 198511
. . . 94 . . . . . . . . . . . . . . 190198
. . . 95 . . FUEL SEND . . 198512
. . . 96 . . . . . . . . . . . . . . 189908
. . . 97 . . . . . . . . . . . . . . 124253
. . . 98 . . . . . . . . . . . . . . 199500
. . . 99 . . . . . . . . . . . . +197835
. . 100 . . . . . . . . . . . . . 197930
. . 101 . . . . . . . . . . . . . 192477
. . 102 . . . . . . . . . . . . . 199701
. . 103 . . . . . . . . . . Figure 11-2
. . 104 . . . . . . . . . . . . . 168385
. . 105 . . . . . . . . . . . . +198158
. . 105 . . . . . . . . . . . ♦198 874
. . 106 . . . . . . . . . . . . . 200653
. . . . . . . . . . . . . . . . . . . . 204773
. . . . . . . . . PLG18 . . . 131198
. . . . . . . . . . . . . . . . . . . . 194126
. . . . . . . . . . . . . . . . . . . . 209496
. . Strap, Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Support, Fuel Tank/Weld Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tank, Fuel 13.1 Gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ftg, Stand Pipe Hose .3125 X24.570lg 90 Deg Zinc . . . . . . . . . . . . . . .
. . . . Ftg, Stand Pipe Hose .1875x24.570lg 90 Deg Zinc . . . . . . . . . . . . . . . .
. . . . Cap, Tank Screw–on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . .
. . . . Sender, Fuel Gauge 22.500 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Tank, Fuel 13.1 Gal Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Mount, Generator Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Front Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Generator Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Generator Right Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Heater, Block Engine 120v 400w Kabota 905 . . . . . . . . . . . . . . . . . . . . . . . .
. . Plug, W/Leads (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Mini 045 3skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . Kit, Acoustical Foam Noise Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Label (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
♦Optional
*Recommended Spare Parts.
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 209 496.
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-4413 Page 64
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-4413 Page 65
Hardware is common and
not available unless listed.
15
45
44
1
2
3
9
4
10
5
6
11
43
7
42
8
12
41
13
14
40
39
38
37
36
16
35
34
18
33
19
20
32
17
8
21
22
31
29
28
24
27
30
26
25
23
803 270
Figure 11-2. Panel, Front w/Components
OM-4413 Page 66
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Panel, Front w/Components (Figure 11-1 Item 103)
. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . 207088 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 115440 . . Stand–off, No 6–32 X .687 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . PC2 . . . . 215235 . . Circuit Card Assy, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 207781 . . Harness, Control Power Board Interconnecting (consisting of) . . . . . . . . .
. . . . . . . . . PLG16 . . . 114655 . . . . Conn, Rect Mini 045 6skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG12,PLG27 . . 117037 . . . . Conn, Rect Mini 045 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG21 . . . 113750 . . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 206794 . . Shield, Pcb Protective Anti Static 4.813x12.750 . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 207779 . . Harness, Remote Control 14pin (consisting of) . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . RC4 . . . . 143976 . . . . Conn, Circ Ms/Cpc 14skt Size 20 Rcpt Panel Pushin (Service Kit) . . . .
. . . . . . . . . PLG24 . . . 131054 . . . . Conn, Rect Mini 045 2skt 2row Plug Cable Lkg (Service Kit) . . . . . . . . .
. . . . . . . . . . RC23 . . . . 115093 . . . . Conn, Rect Mini 045 6skt 2row Plug Cable Lkg (Service Kit) . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 202884 . . Harness, Switch Control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG20 . . . 131198 . . . . Conn, Rect Mini 045 3skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . S3 . . . . . 011609 . . . . Switch,Tgl Spdt 15a 125vac On–none–on Spd Term Chr . . . . . . . . . . .
. . . 7 . . . . PC5 . . . . 148030 . . Circuit Card Assy, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . 134201 . . Stand–off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . .
. . . 9 . . . . . S2 . . . . . 176606 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 207783 . . Harness, Wrg Interconnecting (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG25 . . . 113752 . . . . Conn, Rect Mini 045 10skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . . . . . . . RC7,RC9 . . 136924 . . . . Conn, Rect Comm 093 2p/S 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . .
. . . 10 . . . . . S7 . . . . . 011609 . . . . Switch,Tgl Spdt 15a 125vac On–none–on Spd Term Chr . . . . . . . . . . .
. . . 11 . . . . . S6 . . . . . 021467 . . Switch, Tgl Spst 3a 250v Off–none–(On) Spd Term (Included In Ignition
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness, See Figure 11-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . CB5,CB6 . . 083432 . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . CB3,CB4 . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . GFCI-2,GFCI-3 . 151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5–20r Gfi . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . 198049 . . Upright, Base Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . CB1 . . . . 203026 . . Circuit Breaker, Man Reset 2p 50a 240vac Screw–90 . . . . . . . . . . . . . . . .
. . . 17 . . . . PC3 . . . . 148021 . . Circuit Card Assy, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . 129524 . . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . 099255 . . Terminal, Pwr Output Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . 083030 . . Stud, Brs .250–20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . 601836 . . Nut, 250–20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . 188039 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . 203016 . . Boot, Circuit Breaker 2 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . 206795 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . FG . . . . . 192265 . . Gauge, Fuel Elec Switch W/O Switchgage Sensor . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . HM . . . . . 145247 . . Meter, Hour 12–24vdc 1.25 X 2.12 Rect . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . 119014 . . Lever, Switch Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . RC1 . . . . 182954 . . Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14–50 . . . . . . . . . . . . . . . . . . . . .
. . . 31 . PL1,PL2,PL3 . 206879 . . Light, Ind Amber Lens 12v Snap–in Mtg .500 Mtg Hol . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . 115493 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . 097924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . .
. . . 39 . . . . CT1 . . . . 207786 . . Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . . . 025248 . . Stand–off, Insul .250–20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . V . . . . . . . . . . ♦ . . Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . A . . . . . . . . . . ♦ . . Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . S1 . . . . . 207577 . . Switch, Changeover Assy W/Leads (consisting of) . . . . . . . . . . . . . . . . . . .
. . . 44 . . . . . . . . . . . . . 187 189 . . . . Bracket, Shunt Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 45 . . . . LEM . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . .
1
1
3
1
1
1
2
1
1
1
1
1
1
1
1
1
1
3
1
1
1
2
1
1
2
2
2
1
1
1
1
3
1
3
3
1
1
3
4
1
1
1
1
3
3
3
3
1
1
1
1
1
1
1
1
1
1
1
OM-4413 Page 67
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Panel, Front w/Components (Continued)
....................
. . . . . . . . . . RC29 . . . .
. . . . . . . . . . PLG6 . . . .
. . . . . . . . . . RC30 . . . .
♦Optional
+
209831
113751
204640
136924
. . Receptacles, W/Leads (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Mini 045 8skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . Cable,Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Comm 093 2p/S 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . .
1
1
1
1
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 209 496.
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.
7
6
8
9
5
10
4
1
3
2
11
13
12
19
14
18
15
16
17
803 273
Figure 11-3. Stabilizer/Rectifier/Control Box Assembly
OM-4413 Page 68
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Stabilizer/Rectifier/Control Box Assembly (Figure 11-1 Item 22)
. . . 1 . . . . SR1 . . . . 198514 . . Rectifier, Si 3ph 350 Amp 400 Piv 100% Duty Cycle . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 010381 . . Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 207791 . . Harness, Wrg Ignition (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . CR1,CR2 . . 173069 . . . . Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . 2T . . . . . 197147 . . . . Block, Term 5–4–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . . 158465 . . . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . . 021467 . . . . Switch, Tgl Spst 3a 250v Off–none–(On) Spd Term (On Front Panel,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Figure 11-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . . 092670 . . . . Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG15 . . . 113751 . . . . Conn, Rect Mini 045 8skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG19 . . . 113752 . . . . Conn, Rect Mini 045 10skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG35 . . . 114063 . . . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . . 177859 . . . . Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . RC7 . . . . 136925 . . . . Conn, Rect Comm 093 2p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG31, PLG33 . 135134 . . . . Conn, Rect Univ 084 9p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG17 . . . 066104 . . . . Conn, Rect Univ 084 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC32 . . . . 148389 . . . . Conn, Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187654 . . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG34 . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 004214 . . Bushing, Snap–in Nyl 1.625 Id X 2.000 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 097132 . . Stand–off, No 6–32 X .375 Lg .250 Hex Brs M&f . . . . . . . . . . . . . . . . . . . . 10
. . . 6 . . . . PC1 . . . . 212701 . . Circuit Card Assy, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 209355 . . Cover, PCB Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . C25 . . . . 176007 . . Capacitor, Elctlt 1200 Uf 300 Vdc Can 1.37 Dia . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . PC7 . . . . 203130 . . Circuit Card Assy, Gen Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . R1 . . . . . 188067 . . Resistor, Ww Fxd 100 W 200 Ohm W/Clips . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . +207803 . . Bracket, Mtg Pc Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 200263 . . Label, Warning Electric Shock Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 202331 . . Gasket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 204166 . . Bracket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . DC-Z . . . . 207664 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 207733 . . Frame, Mtg Stab/Rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . 1T . . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . 207735 . . Bracket, Mtg Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 209 496.
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-4413 Page 69
Item
No.
Part
No.
Description
Quantity
Figure 11-4. Generator (Figure 11-1 Item 36)
. . . 1 . . . . . . . . . . . . . . 210438
. . . 2 . . . . . . . . . . . . . . 183419
. . . 3 . . . STATOR . . +207637
. . . 4 . . . . . . . . . . . . . . 013367
. . . 5 . . . ROTOR . . . 207591
. . . 6 . . . . . . . . . . . . . . 181143
. . . 7 . . . . . . . . . . . . . . 192600
. . . 8 . . . . . . . . . . . . . . 159918
. . . 9 . . . . . . . . . . . . . . 193515
. . . 10 . . . . . . . . . . . . . . 170861
. . . 11 . . . BRUSH . . . 205725
. . . . . . . . . . . . . . . . . . . . 207640
. . . . . . . . . PLG32 . . . 114063
. . . 12 . . . . . . . . . . . . . . 010910
. . . 13 . . . . . . . . . . . . . . 010909
. . Endbell (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stator, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Moving Parts Can Cause Serious Injury . . . . . . . . . . . . . . . . . . . . . .
. . Rotor, Generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . .
. . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Adapter, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stud, Stl .375–16 X 17.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Plug, W/Leads Brushholder (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . Washer, Flat .406 ID x 0.812 OD x .065t Stl Pld Ansi .375 . . . . . . . . . . . .
. . Nut, .375-16 .56 hex .46h Stl Pld Elastic Stop . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
4
2
1
1
4
4
Hardware is common and
not available unless listed.
9
8
5
7
6
4
3
10
1
2
11
12
803 271
13
Figure 11-4. Generator
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 209 496.
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-4413 Page 70
Effective January 1, 2002
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
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
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 6/03
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2003 Miller Electric Mfg. Co.
1/03
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