Miller Electric Big 40 WG Owner`s manual

OM-4405
200 972A
January 2001
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
Big 40 WG
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller.
Now you can get the job done and get it done right. We
know you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller
products had to be more than the best they could be.
They had to be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
Miller is the first welding help you figure out what the problem is. The
equipment manufacturer in parts list will then help you to decide which
the U.S.A. to be registered to
the ISO 9001 Quality System exact part you may need to fix the problem.
Standard.
Warranty and service information for your
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
WARNING
Battery posts, terminals
and related accessories
contain lead and lead
compounds, chemicals
known to the State of
California to cause
cancer and birth defects
or other reproductive
harm. Wash hands after
handling.
WARNING
The engine exhaust from
this product contains
chemicals known to the
State of California to
cause cancer, birth
defects, or other
reproductive harm.
The following terms are
used interchangeably
throughout this manual:
Stick = SMAW
TIG = GTAW
MIG = GMAW
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
3
4
4
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
6
7
8
8
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Volt-Ampere Curves For CC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Volt-Ampere Curves for CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. AC Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Optional AC Power Plant Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
10
10
11
12
12
13
13
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator (See Sections 4-2 And 4-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Selecting Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models . . . . . . . . . . . . .
4-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models . . . . . . . . . . . . . . . . . . . . . .
14
14
14
15
15
16
17
18
19
19
20
21
SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls For CC Models (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Description Of Front Panel Controls For CC Models (See Section 5-1) . . . . . . . . . . . . . . . . .
5-3. Remote Amperage Control On CC Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
22
23
24
SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls For CC/CV Models (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1) . . . . . . . . . . . . . .
6-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) . . . . . . . . . . . . . . . . . . . . .
26
26
27
28
29
SECTION 7 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. 120 Volt And 240 Volt Duplex Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only) . . . . . . . . . . . . . . . . . .
7-3. Optional Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
30
31
32
(Continued)
TABLE OF CONTENTS
SECTION 8 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Adjusting Engine Weld/Power Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Adjusting Engine Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Adjusting Governor Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Diagnosing Causes Of Engine Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
33
34
35
36
37
38
39
40
41
42
43
SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
SECTION 10 – AUXILIARY POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
OPTIONS AND ACCESSORIES
WARRANTY
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
rom _nd_11/98
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters.
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
ARC RAYS can burn eyes and skin.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first – double-check connections.
Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes from arc rays and sparks when welding or
watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-4405 Page 1
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
HOT PARTS can cause severe burns.
Allow cooling period before maintaining.
Wear protective gloves and clothing when
working on a hot engine.
Do not touch hot engine parts or just-welded
parts bare-handed.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
CYLINDERS can explode if damaged.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Engine Hazards
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank – allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
OM-4405 Page 2
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before completely
removing cap.
MOVING PARTS can cause injury.
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (–) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
BATTERY ACID can BURN SKIN and
EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE EXHAUST GASES can kill.
Use equipment outside in open, well-ventilated
areas.
If used in a closed area, vent engine exhaust
outside and away from any building air intakes.
ENGINE HEAT can cause fire.
BATTERY EXPLOSION can BLIND.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and –) on batteries.
Disconnect negative (–) cable first and connect it last.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas – see applicable codes.
1-4. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, trailer, or any other
accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
FLYING SPARKS can cause injury.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or
stopping engine.
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
READ INSTRUCTIONS.
Use only genuine MILLER replacement parts.
Perform engine maintenance and service
according to this manual and the engine
manual.
OM-4405 Page 3
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-5. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
2. Arrange cables to one side and away from the operator.
OM-4405 Page 4
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT
UTILISATION
rom _nd_fre 11/98
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Identifie un message de sécurité particulier.
Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-5. Veuillez lire et respecter toutes
ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des composants.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès
que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact avec
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la
terre présentent un danger.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec
la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets et
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas
de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel
avec la pièce ou la terre.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation,
à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre
du sectionneur ou que la fiche du cordon est raccordée à une prise
correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de
mise à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct – ne pas utiliser le connecteur de pièce ou le câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
une électrode provenant d’une autre machine.
Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de
l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
Porter des vêtements de protection constitué dans une matière durable, résistant au feu (laine ou cuir) et une protection des pieds.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des
blessures ou des accidents mortels. S’assurer que l’air de respiration ne
présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et
tous les métaux renfermant ces éléments peuvent dégager des fumées
toxiques en cas de soudage.
OM-4405 Page 5
LE SOUDAGE peut provoquer un incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels que
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles peuvent être projetées de
l’arc de soudure. La projection d’étincelles, des pièces chaudes et des
équipements chauds peut provoquer des incendies et des brûlures. Le contact
accidentel de l’électrode avec des objets métalliques peut provoquer des
étincelles, une explosion, un surchauffement ou un incendie. Avant de
commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
Prévoir une période de refroidissement avant d’effectuer des travaux d’entretien.
Porter des gants et des vêtements de protection pour
travailler sur un moteur chaud.
Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
récemment soudées.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec
précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou
dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
substances inflammables.
Déplacer toutes les substances inflammables à une distance de 10,7 m de
l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec
des protections homologués.
Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des
ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés
correctement conformément à AWS F4.1 (voir les normes de sécurité).
Brancher le câble sur la pièce le plus près possible de la zone de soudage
pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et
d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porte-électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des gants
en cuir, une chemise en matériau lourd, des pantalons sans revers, des
chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches telles
qu’un allumeur au butane ou des allumettes.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Ne jamais souder une bouteille pressurisée – risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords convenables pour cette application spécifique; les maintenir ainsi
que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
les équipements associés et les publication P-1 CGA énumérées dans les
normes de sécurité.
1-3. Dangers existant en relation avec le moteur
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
OM-4405 Page 6
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Toujours vérifier le niveau de liquide de refroidissement dans le vase
d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme
suivant :
Mettre des lunettes de sécurité et des gants, placer un torchon sur le
bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
DES ORGANES MOBILES peuvent
provoquer des blessures.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas approcher les mains des ventilateurs, courroies et autres pièces en mouvement.
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
Arrêter le moteur avant d’installer ou brancher l’appareil.
Demander seulement à un personnel qualifié d’enlever les dispositifs de
sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux
d’entretien et de dépannage.
Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, débrancher le câble négatif (–) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles.
Remettre en place les panneaux ou les dipositifs de protection et fermer
les portes à la fin des travaux d’entretien et avant de faire démarrer le
moteur.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise
en route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention
sur le générateur.
L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.
Toujours porter une protection faciale, des gants en
caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher les câbles de
batterie.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide.
Observer la polarité correcte (+ et –) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier
lieu.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
LES GAZ D’ÈCHAPPEMENT DU
MOTEUR peuvent provoquer des
accidents mortels.
Utiliser l’équipement à l’extérieur dans des zones ouvertes et bien ventilées.
En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappement du moteur vers l’extérieur à distance des entrées d’air dans les bâtiments.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces inflammables.
Tenir à distance les produits inflammables de
l’échappement.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé –
voir codes en vigueur.
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
LA CHUTE DE L’APPAREIL peut
blesser.
Utiliser l’anneau de levage uniquement pour soulever
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.
Utiliser un équipement de levage de capacité suffisante pour lever l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
Porter un écran facial pour protéger le visage et les
yeux.
Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque
l’on porte l’équipement homologué de protection du visage, des mains et
du corps.
Les étincelles risquent de causer un incendie – éloigner toute substance
inflammable.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
LES
CHARGES
ÉLECTROSTATIQUES
peuvent
endommager les circuits imprimés.
Établir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
LE SURCHAUFFEMENT peut endommager le moteur électrique.
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
Utiliser les supports de la remorque ou des blocs
pour soutenir le poids.
Installer convenablement le poste sur la remorque
comme indiqué dans le manuel s’y rapportant.
Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur.
Ne pas laisser tourner le moteur trop lentement sous
risque d’endommager le moteur électrique à cause
d’une tension et d’une fréquence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a
lieu.
LIRE LES INSTRUCTIONS.
Utiliser seulement les pièces de rechange d’origine.
Effecteur la maintenance et la mise en service
d’après le manuel et celui du moteur.
OM-4405 Page 7
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements
de radio–navigation et de communication, les
services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées avec des
équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des sources
de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et et un blindage pour réduire les interférences
éventuelles.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible
électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que
le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
1-5. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
OM-4405 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
SECTION 2 – DEFINITIONS
2-1. Symbols And Definitions
A
Stop Engine
Fast (Run, Weld/
Power)
Slow (Idle)
Start Engine
Air Temperature Or
Engine
Temperature
Battery (Engine)
Engine Oil
Pressure
Engine Oil
Engine
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
Panel/Local
Remote
Electrode
Connection
Work Connection
Output
Alternating
Current
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
TIG (GTAW)
Amperes
Time
3
V
Hours
h
s
Three Phase
Read Operator’s
Manual
Engine Choke
Contactor On
Seconds
1
Single Phase
Do Not Switch
While Welding
Circuit Breaker
Hz
Hertz
SECTION 3 – SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
CC/DC
Weld Output
Range
Rated Welding
Output
45 – 500 A
(CC Models)
15 – 500 A
(CC/CV Models)
Maximum
OpenCircuit
Voltage
95
300 A, 40 Volts DC,
100% Duty Cycle
400 A, 40 Volts DC,
60% Duty Cycle
CV/DC
(CC/CV
Models
Only)
14 – 40 V
500 A, 30 Volts DC,
40% Duty Cycle
56
Auxiliary Power Rating
Standard
Single-Phase,
4 kVA/kW, 34/17 A,
120/240 V AC,
50/60 Hz
Full kVA Option*
Single-Phase/Three-Phase,
12/15 kVA/kW, 50/36A,
120/240 VAC, 60 Hz
Fuel
Capacity
Engine
Wis.Con
Wis-Con TM-20
Water-Cooled,
Three-Cylinder,
38 HP Gasoline
Engine
25 gal
(95 L)
*In Addition To Standard
4 kVA/kW Auxiliary Power
OM-4405 Page 9
3-2. Dimensions, Weights, And Operating Angles
Dimensions
58 in (1473 mm)
(to top of muffler)
Height
G
28-1/2 in (724 mm)
(mtg. brackets turned in)
Do not exceed tilt angles or engine could
be damaged or unit could tip.
30-3/4 in (781 mm)
(mtg. brackets turned out)
Do not move or operate unit where it could
tip.
Width
Depth
64-7/16 in (1637 mm)
A
64-7/16 in (1637 mm)
B
55-7/8 in (1419 mm)
C
46-3/8 in (1178)
D
9-1/2 in (241 mm)
E
27-1/2 in (699 mm)
A
B
C
30°
H
F
1 in (25 mm)
G
29-1/2 in (743 mm)
H
9/16 in (14 mm) Dia.
4 Holes
D
20°
30°
20°
Front Panel End
F
Weight
E
No fuel: 1600 lb (726 kg)
w/fuel: 1775 lb (805 kg)
802 161-A
802 729
3-3. Volt-Ampere Curves For CC Models
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
100
Ranges
210 – Max
165 – 350
100 – 250
65 – 120
45 – 85
DC VOLTS
80
60
40
20
0
0
100
200
300
400
DC AMPERES
500
600
700
202 666-A
OM-4405 Page 10
3-4. Volt-Ampere Curves for CC/CV Models
A. Stick Mode
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
100
Ranges
Max
150 – 420
110 – 315
75 – 200
40 – 90
DC VOLTS
80
60
40
20
0
0
100
200
300
400
500
600
700
800
900
DC AMPERES
B. MIG Mode
100
DC VOLTS
80
60
MAX
40
20
MIN
0
0
100
200
300
400
500
600
700
800
900
1000
450
500
DC AMPERES
C. TIG Mode
100
90
Ranges
50 – 335
40 – 240
25 – 150
15 – 75
80
DC VOLTS
70
60
50
40
30
20
10
0
0
50
100
150
200 250 300
DC AMPERES
350
400
202 655 / 202 656 / 202 654
OM-4405 Page 11
3-5. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
2.50
2.25
U.S. Gal./Hr.
2.00
1.75
1.50
1.25
1.00
0.75
IDLE
0.50
0.25
0.00
0
50
100
150
200
250
300
350
400
DC WELD AMPERES AT 100% DUTY CYCLE
201 033
3-6. Duty Cycle And Overheating
100% Duty Cycle At 300 Amperes
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
Exceeding duty cycle can
damage unit and void
warranty.
WELD AMPERES
Continuous Welding
% DUTY CYCLE
199 140
OM-4405 Page 12
3-7. AC Auxiliary Power Curve
The ac power curve shows the auxiliary power in amperes available at
the 120 and 240 volt receptacles.
150 300
AC VOLTS
125 250
100 200
75 150
50 100
25
50
0
0
0
0
5
10
15
20
AC AMPERES IN 240V MODE
10
20
30
40
AC AMPERES IN 120V MODE
25
30
50
60
193 018
3-8. Optional AC Power Plant Curves
A. 12 kVA/kW Single-Phase Auxiliary Power Plant (No Weld Load)
280
The ac power curves show the auxiliary power available in amperes at
the single-phase 120/240 volt receptacle or three-phase 240 volt
terminals.
AC VOLTS
260
240
220
200
180
0
20
40
60
80
100
AC AMPERES
B. 15 kVA/kW Three-Phase Auxiliary Power Plant (No Weld Load)
280
AC VOLTS
260
240
220
200
180
0
10
20
30
40
AC AMPERES
50
60
70
198 868 /98 869
OM-4405 Page 13
SECTION 4 – INSTALLATION
4-1. Installing Welding Generator (See Sections 4-2 And 4-3)
Movement
Airflow Clearance
Location
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
OR
OR
18 in
(460 mm)
18 in
(460 mm)
Always securely fasten
welding generator onto
transport vehicle or trailer
and comply with all DOT and
other applicable codes.
Grounding
3
1
4
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
GND/PE
OR
2
1
2
3
Electrically bond generator frame to
vehicle frame by metal-to-metal
contact.
4
2
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
If unit does not have GFCI receptacles,
use
GFCIprotected extension cord.
install2 1/01 – Ref. 800 652 / Ref. 800 477-A / 158 936-A / 0854
4-2. Using Lifting Eye
1
2
3
1
Lifting Eye
Nut
Carriage Bolt
Raise lifting eye until it snaps in
place. Lower lifting eye when not
needed.
2
3
To lock the lifting eye in the up-
right position, insert a 3/8-16 x
1-1/2 in carriage bolt through
slot in bracket and secure with
nut (bolt and nut not supplied).
Tools Needed:
Ref. 802 729
OM-4405 Page 14
4-3. Mounting Welding Generator
Do not weld on base. Welding on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
1
1
2
3
Mounting Bracket
1/2 in Bolt And Washer (Not
Supplied)
3/8-16 x 1 in Screws
(Supplied)
To Bolt Unit In Place:
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
Welding Unit In Place
Bolting Unit In Place
2
1
Mount unit to truck or trailer with 1/2
in (12 mm) hardware (not supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
Tools Needed:
9/16 in
3
Ref. 190 250-A / Ref. 802 730
4-4. Installing Exhaust Pipe
Stop engine and let cool.
Engine backfire can cause severe burns or other injuries. Do
not point exhaust pipe toward
control panel. Keep away from
exhaust outlet.
Point exhaust pipe in desired di-
rection but always away from
front panel and direction of travel.
Tools Needed:
1/2 in
Ref. 802 730 / Ref. 201 841
OM-4405 Page 15
4-5. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1
5
4
1
2
3
4
5
Eye Protection – Safety
Glasses Or Face Shield
Rubber Gloves
Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
Well
Fill each cell with electrolyte to
bottom of well (maximum).
3
Do not overfill battery cells.
Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
6
Battery Charger
Read and follow all instructions supplied with battery
charger.
2
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 amperes. Disconnect charging cables
and install battery.
When electrolyte
is low, add
only distilled water to cells to
maintain proper level.
6
5 A For 30 Minutes
Tools Needed:
OR
+
–
rubber gloves
30 A For 12 Minutes
glasses
drybatt1 1/98 – 0886
OM-4405 Page 16
4-6. Connecting The Battery
Connect Negative (–) Cable Last.
+
–
Tools Needed:
1/2 in
802 168-B / Ref. 201 841 / 802 313 / S-0756-C
Notes
OM-4405 Page 17
4-7. Engine Prestart Checks
Check radiator coolant level when
fluid is low in recovery tank.
Full
Capacity: 9 qt (8.5L)
Full
Gasoline
Full
Coolant Recovery Tank
Hot Full
Cold Full
802 731
Check all engine fluids daily.
time (see engine maintenance label for fuel
specifications).
Engine must be cold and on a level surface.
Unit is shipped with 20W break-in oil.
Oil
Automatic shutdown system stops engine if
oil pressure is too low, or coolant temperature is too high.
This unit has a low oil pressure shut-
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual.
Fuel
Add fresh fuel before starting engine the first
OM-4405 Page 18
After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Coolant
Check coolant level in radiator before starting unit the first time. If necessary, add coolant to radiator until coolant level is at bottom
of filler neck.
Check coolant level in recovery tank daily.
If necessary, add coolant to recovery tank
until coolant level is between Cold Full and
Hot Full levels. If recovery tank coolant level
was low, also check coolant level in radiator.
Add coolant if level is below bottom of radiator filler neck.
Engine coolant is a mixture of water and
ethylene glycol base antifreeze. Add antifreeze to mixture if using the unit in temperatures below –34° F (–37° C).
Keep radiator and air intake clean and free
of dirt.
Incorrect engine temperature can
damage engine. Do not run engine
without a properly working thermostat and radiator cap.
To improve cold weather starting:
Keep battery in good condition. Store
battery in warm area off concrete surface.
Use correct grade oil for cold weather
(see Section 8-1).
4-8. Connecting To Weld Output Terminals
Stop engine.
Tools Needed:
3/4 in
1
Positive (+) Weld Output Terminal
2
Negative (–) Weld Output Terminal
For Stick and TIG welding Direct Current
Electrode Positive (DCEP), connect
electrode holder cable to Positive (+) terminal on left and work cable to Negative
(–) terminal on right.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional polarity switch,
connect electrode holder cable to Electrode terminal on left and work cable to
Work terminal on right.
For MIG and FCAW welding Direct Current Electrode Positive (DCEP) on CC/
CV models, connect wire feeder cable to
Positive (+) terminal on left and work
cable to Negative (–) terminal on right.
Use Process/Contactor switch to select
type of weld output (see Section 6-3).
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
1
If equipped with optional polarity switch,
connect wire feeder cable to Electrode
terminal on left and work cable to Work
terminal on right.
2
802 729
4-9. Selecting Weld Cable Sizes
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
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)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
Do not use worn, damaged, undersized, or
poorly spliced cables.
10 – 100% Duty Cycle
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-E–
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
OM-4405 Page 19
4-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models
1
Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
RC13 (see Section 5-3).
1
Ref. 154 862-A / 048 720-K / 802 729
OM-4405 Page 20
4-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
Socket*
Socket Information
A
24 volts ac. Protected by circuit
breaker CB5.
B
Contact closure to A completes
24 volt ac contactor control
circuit.
C
Output to remote control:+10
volts dc in MIG or Stick mode;
0 to +10 volts dc in TIG mode.
D
Remote control circuit common.
E
DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
K
Chassis common.
G
Circuit common for 24 volt ac
circuit.
24 VOLTS AC
New! LDR-14 long
distance remote
(includes 120 V
receptacle)
REMOTE
OUTPUT
CONTROL
OR
GND
802 729
NEUTRAL
*The remaining sockets are not used.
OM-4405 Page 21
SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS
5-1. Front Panel Controls For CC Models (See Section 5-2)
5
13
14
18
19
10 11
6
4
12
7
9
8
2
15
16
3
1
17
201 841 / 802 729
OM-4405 Page 22
5-2. Description Of Front Panel Controls For CC Models (See Section 5-1)
Engine Starting Controls
1 Magnetic Shutdown Switch
Use switch during start-up to bypass engine
shutdown system. System stops engine if oil
pressure is too low or coolant temperature is
too high.
2 Starting Aid (Engine Choke Control)
Use control to change engine air-fuel mix.
3 Engine Control Switch
Use switch to start engine, select engine
speed, and stop engine.
In Run position, engine runs at weld/power
speed. In Run/Idle position, engine runs at
idle speed at no load and weld speed with load
applied.
To Start:
If engine does not start, let engine come
to a complete stop before attempting restart.
Pull Choke control out. Turn Engine Control
switch to Start while pressing Shutdown
switch. Release Engine Control switch when
engine starts. Continue holding Shutdown
switch until engine indicator lights go out.
Push Choke control in.
To Stop: turn Engine Control switch to Off
position.
Engine Indicator Lights
4 Battery Charging Light
Light goes on if engine alternator is not charging battery. Engine continues to run.
Stop engine and fix trouble if Battery
Charging light goes on.
5 Engine Temperature Light
Light goes on and engine stops if engine temperature is above 230 ° F (110° C).
Stop engine and fix trouble if Engine
Temperature light goes on.
6 Engine Oil Pressure Light
Light goes on and engine stops if oil pressure
is below 5 psi (34 kPa). Light goes on momentarily during start-up but goes out when engine reaches normal oil pressure.
Stop engine and fix trouble if Engine
Oil Pressure light stays on after startup.
7 Fuel Light
Fuel light is not active on this model.
8
Engine Hour Meter
Engine Gauges
amperage range possible to help prevent arc
outages.
To
14 Amperage Adjust Control
9
The numbers around the control are for
read gauges and engine indicator
lights with engine off, turn Engine Control
switch to Run/Idle and press Magnetic
Shutdown switch (see Section 8-10).
Fuel Gauge
Use gauge to check fuel level.
To check fuel level when engine is not running, turn Engine Control switch to Run/Idle
position and press Magnetic Shutdown
switch.
10 Battery Voltmeter (Optional)
Use gauge to check battery voltage and monitor the engine charging system. The meter
should read about 14 volts dc when the engine is running, and about 12 volts dc when
the engine is stopped.
11 Engine Coolant Temperature Gauge
(Optional)
Normal temperature is 180 - 203° F (82 - 95°
C). When equipped with gauge option, engine
stops if temperature exceeds 220° F (104° C).
12 Engine Oil Pressure Gauge (Optional)
Normal pressure is 30 – 80 psi (207 – 552
kPa). When equipped with gauge option, engine stops if pressure is below 10 psi (69
kPa).
Weld Controls
Max OCV Control Circuit: This unit has
a max OCV control circuit that resets Amperage Adjust control R1 to maximum
when the arc breaks. When an arc is
struck, weld output control returns to the
R1 front panel or combination front panel/
remote control setting. The Amperage
Adjust control adjusts amperage only
when welding and does not adjust opencircuit voltage.
The max OCV circuit is disabled when
the Stick/TIG Selection switch is in
Scratch Start TIG position (see item 15).
Control adjusts amperage within range selected by Ampere Range switch. Weld output
would be about 153 A DC with controls set as
shown (50% of 100 to 205 A).
reference only and do not represent an
actual percentage value.
15 Stick/TIG Selection Switch
Use switch to disable the max OCV circuit
and the arc drive (dig) circuit for scratch start
TIG welding (see max OCV note under Weld
Controls).
When switch is in the Stick position, the max
OCV circuit resets Amperage Adjust Control
R1 to maximum when the arc breaks.
Also in the Stick position, the arc drive (dig)
circuit provides additional amperage during
low voltage (short arc length conditions) to
prevent “sticking” electrodes.
When switch is in Scratch Start TIG position,
the max OCV and arc drive (dig) circuits are
disabled and OCV changes when the control
is adjusted.
16 Amperage Adjust Switch And Remote
Amperage Adjust Receptacle
Connect optional remote control to RC13
(See Section 4-10). Use switch to select front
panel or remote amperage control. For remote control, place switch in Remote position
and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 4-10 and 5-3).
17 Polarity Switch (Optional)
Do not switch under load.
Use switch to change weld output. Select either DC Electrode Positive (DCEP) or DC
Electrode Negative (DCEN).
Weld Meters
18 DC Voltmeter (Optional)
13 Ampere Range Switch
Voltmeter displays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
Do not switch under load.
19 DC Ammeter (Optional)
Use switch to select weld amperage range.
For most welding applications, use lowest
Ammeter displays amperage output of the
unit.
OM-4405 Page 23
5-3. Remote Amperage Control On CC Models (Optional)
1
Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
RC13 (see Section 4-10).
1
In Example:
Range = 100 to 205 A DC
Percentage Of Range = 50%
Max = About 153 A DC (50% of 100 to 205)
Example: Combination Remote Amperage Control (Stick)
Max (153 A DC)
Min (75 A DC)
Set Switches
Set Range
Set Control
Adjust Optional Remote Control
0774 / Ref. 154 862-A / Ref. 181 711-A / 802 729
OM-4405 Page 24
Notes
OM-4405 Page 25
SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS
6-1. Front Panel Controls For CC/CV Models (See Section 6-2)
5
14
15
18
19
10 11
6
4
12
7
9
8
2
13
16
3
1
17
201 579 / 802 729
OM-4405 Page 26
6-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1)
Engine Starting Controls
1
Magnetic Shutdown Switch
Use switch during start-up to bypass engine
shutdown system. System stops engine if oil
pressure is too low or engine temperature is
too high.
2
Starting Aid (Engine Choke Control)
tarily during start-up but goes out when engine reaches normal oil pressure.
Stop engine and fix trouble if Engine
Oil Pressure light stays on after startup.
7 Fuel Light
Fuel light is not active on this model.
Use control to change engine air-fuel mix.
8
3
Engine Gauges
Engine Control Switch
Use switch to start engine, select engine
speed, and stop engine.
In Run position, engine runs at weld/power
speed. In Run/Idle position, engine runs at
idle speed at no load and weld speed with load
applied.
To Start:
If engine does not start, let engine come
to a complete stop before attempting restart.
Pull Choke control out. Turn Engine Control
switch to Start while pressing Shutdown
switch. Release Engine Control switch when
engine starts. Continue holding Shutdown
switch until engine indicator lights go out.
Push Choke control in.
To Stop: turn Engine Control switch to Off
position.
Engine Indicator Lights
4
Battery Charging Light
Light goes on if engine alternator is not charging battery. Engine continues to run.
Stop engine and fix trouble if Battery
Charging light goes on.
5
Engine Temperature Light
Light goes on and engine stops if engine temperature is above 230 ° F (110° C).
Engine Hour Meter
To
read gauges and engine indicator
lights with engine off, turn Engine Control
switch to Run/Idle and press Magnetic
Shutdown switch (see Section 8-10).
9
Fuel Gauge
Use gauge to check fuel level.
To check fuel level when engine is not running, turn Engine Control switch to Run/Idle
position and press Magnetic Shutdown
switch.
10 Battery Voltmeter (Optional)
Use gauge to check battery voltage and monitor the engine charging system. The meter
should read about 14 volts dc when the engine is running, and about 12 volts dc when
the engine is stopped.
11 Engine Coolant Temperature Gauge
(Optional)
Normal temperature is 180 - 203° F (82 - 95°
C). When equipped with gauge option, engine
stops if temperature exceeds 220° F (104° C).
For most welding applications, use lowest
amperage range possible to help prevent arc
outages.
15 Voltage/Amperage Adjust Control
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage
within range selected by Ampere Range
switch. With Process/Contactor switch in any
MIG position, use control to adjust voltage.
With Voltage/Amperage Adjust Switch in Remote position, control limits the remote amperage in TIG mode, but has no effect in Stick
and MIG modes.
Weld output would be about 213 A DC with
controls set as shown (50% of 110 to 315 A).
The numbers around the control are for
reference only and do not represent an
actual percentage value.
16 Voltage/Amperage Adjust Switch And
Remote 14 Receptacle
Use switch to select front panel or remote
voltage/amperage control. For remote control, place switch in Remote position and connect remote control to Remote 14 receptacle
RC14 (see Sections 4-11 and 6-4).
17 Polarity Switch (Optional)
Do not switch under load.
Normal pressure is 30 – 80 psi (207 – 552
kPa). When equipped with gauge option, engine stops if pressure is below 10 psi (69
kPa).
Use switch to change weld output. Select either DC Electrode Positive (DCEP) or DC
Electrode Negative (DCEN).
Weld Controls
13 Process/Contactor Switch
See Section 6-3 for Process/Contactor
switch information.
6
14 Ampere Range Switch
Light goes on and engine stops if oil pressure
is below 5 psi (34 kPa). Light goes on momen-
Use the highest range for MIG welding and for
cutting and gouging (CAC-A).
12 Engine Oil Pressure Gauge (Optional)
Stop engine and fix trouble if Engine
Temperature light goes on.
Engine Oil Pressure Light
Use the lowest four ranges for Stick and TIG
welding. Read the upper set of numbers at
each range for Stick welding and the lower set
at each range for TIG welding.
Do not switch under load.
Use switch to select weld amperage range.
Weld Meters
18 DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
19 DC Ammeter (Optional)
Ammeter displays amperage output of the
unit.
OM-4405 Page 27
6-3. Process/Contactor Switch On CC/CV Models
1
1
Process/Contactor Switch
Weld output terminals are energized when Process/Contactor switch is in an Electrode
Hot position and the engine is
running.
Use switch to select weld process
and weld output on/off control (see
table below and Section 6-4).
Place switch in Remote positions to
turn weld output on and off with a device connected to the remote 14 receptacle.
Place switch in Electrode Hot positions for weld output to be on whenever the engine is running.
Use Stick position for air carbon arc
(CAC-A) cutting and gouging.
When switch is in a Stick position, the
arc drive (dig) circuit provides additional amperage during low voltage
(short arc length conditions) to prevent “sticking” electrodes.
The arc drive (dig) circuit is disabled
when switch is in MIG or TIG
positions.
Place switch in Electrode Hot -
Stick position when using optional auxiliary power plant (see Section 7-2).
The
engine auto idle function
does not work in the Remote-TIG
mode.
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Engine Auto Idle
Remote – TIG
GTAW With HF Unit, Pulsing
Device, Or Remote Control
At Remote 14 Receptacle
Not Active
Remote – Stick
Stick (SMAW) With Remote On/Off
At Remote 14 Receptacle
Active
Remote – MIG
MIG (GMAW)
At Remote 14 Receptacle
Active
Electrode Hot – MIG
MIG (GMAW)
Electrode Hot
Active
Electrode Hot – Stick
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting
And Gouging
Electrode Hot
Active
Electrode Hot – Scratch
Start TIG
Scratch Start TIG (GTAW)
Electrode Hot
Active
OM-4405 Page 28
6-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)
1
Remote 14 Receptacle RC14
Connect optional remote control to
RC14 (see Section 4-11).
1
In Example:
Process = Stick (Using Remote On/Off)
Range = 110 to 315 A DC
Min = 110 A DC
Max = 315 A DC
Example: Combination Remote Amperage Control (Stick)
Max (315 A DC)
Min (110 A DC)
Set V/A
Adjust Switch
Set Remote
Process
Set Range
Control Not
Used In Remote
Stick Mode
Adjust Optional Remote Control
In Example:
Process = TIG (Using Remote On/Off)
Range = 40 to 240 A DC
Percentage Of Range = 50%
Min = 40 A DC
Max = About 140 A DC (50% of 40 to 240)
Example: Combination Remote Amperage Control (TIG)
Max (140 A DC)
Min (40 A DC)
Set V/A
Adjust Switch
Set Remote
Process
Set Range
Set Control
Adjust Optional Remote Control
0774 / Ref. 201 579 / 802 730
OM-4405 Page 29
SECTION 7 – OPERATING AUXILIARY EQUIPMENT
7-1. 120 Volt And 240 Volt Receptacles
1
120 V 20 A AC GFCI
Receptacle GFCI1
2
240 V 30 A AC Twistlock
Receptacle RC1
Receptacles supply 60 Hz singlephase power at weld/power speed.
1
3
2
If a ground fault is detected, GFCI
Reset button pops out and
receptacle does not work. Check
for faulty tools plugged in
receptacle. Press button to reset
GFCI1.
At least once a month, run en-
gine at weld/power speed and
press test button to verify GFCI
is working properly.
4
3
Circuit Breaker CB1
4
Circuit Breaker CB2
CB1 protects RC1 and the generator winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset breaker.
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset breaker.
If a circuit breaker continues to
open, contact Factory Authorized Service Agent.
Auxiliary power is not affected
by weld output.
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all receptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
191 624-A
OM-4405 Page 30
7-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only)
Place Process/Contactor switch
1
Single-Phase Power Connection
in Electrode Hot - Stick position
when using auxiliary power plant
(see Section 6-3).
2
Single-Phase Auxiliary Power
1
120/240 V 50 A Receptacle
RC5
RC5 is connected to the optional
auxiliary power plant and supplies 60
Hz single-phase power at weld/power speed. Maximum output from RC5
is 12 kVA/kW. Power available at
RC5 is reduced when welding.
2
Circuit Breaker CB7
Circuit breaker CB7 protects singlephase receptacle RC5 and the load
wires from overload. If CB7 opens, all
auxiliary power plant output stops
and the receptacle does not work.
Three-Phase Auxiliary Power
Three-Phase Power Connection
Volts
Single
Phase
1
120/240
Three
Phase
3
240
Amps
50
48
KVA/KW
12
20
AC
Output
Close panel opening
if no connections are
made to power plant.
Frequency
Engine Speed
Lead 42 connects to GROUND stud on
front of unit.
Jumper 42 is connected to 90 at factory.
93
91
4
Rear Of Panel
92
93
cording to circuit diagram and
Auxiliary Power Guidelines (see
Section 10).
Remove auxiliary power panel
mounting screws. Tilt panel forward.
3
Lead 93
4
Lead 92
5
Lead 91
90
6
Lead 42 (Circuit Grounding
Lead)
92
7
Lead 90 (Neutral)
5
91
Power and weld outputs are
live at the same time. Disconnect or insulate unused
cables.
Have qualified person install ac-
60 Hz
1850 RPM
Remove plug
before inserting
leads. Reinstall
bushing.
Stop engine.
3
8
Isolated Neutral Terminal
9
Jumper Lead 42
10 Grounding Terminal
6
2
Jumper 42 is connected to lead 90 at
factory. Jumper 42 may be disconnected from neutral to meet applicable electrical codes.
12
7
Lead 42 connects to front panel
Ground stud.
10
11 User-Supplied Leads
12 Circuit Breaker CB7 User
Terminals
11
Close
panel
opening if no
connections
are made to
power plant.
9
240V
8
120V
1-Phase
120V
Tools Needed:
240V
3-Phase
240V
Connect user-supplied leads to terminals on CB7 and to the isolated
neutral terminal and grounding terminal as necessary.
Circuit
breaker CB7 protects
single-phase receptacle RC5
and the load wires from overload.
If CB7 opens, all auxiliary power
plant output stops and the receptacle does not work.
Reinstall auxiliary power panel.
240V
Ref. 197 399 / 802 332-E
OM-4405 Page 31
7-3. Optional Auxiliary Power Receptacles
1
120 V 20 A AC GFCI
Receptacle GFCI1
2
240 V 16 A AC European
Receptacle RC1
3
240 V 15 A AC Australian
Receptacle RC1
4
240 V 15 A AC South African
Receptacle RC1
European Receptacle
5
1
2
6
Receptacles supply 60 Hz singlephase power at weld/power speed.
If a ground fault is detected, the
GFCI Reset button pops out and
the receptacle does not work.
Check for faulty tools plugged in
receptacle. Press button to reset
GFCI1.
At least once a month, run en-
gine at weld/power speed and
press test button to verify GFCI
is working properly.
Australian Receptacle
1
3
5
5
Circuit Breaker CB2
6
Circuit Breaker CB3
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Place button to reset breaker.
6
CB3 protects RC1 from overload. If
CB3 opens, RC1 does not work.
Press button to reset breaker.
If a circuit breaker continues to
open, contact Factory Authorized Service Agent.
Auxiliary power is not affected
by weld output.
South African Receptacle
5
1
4
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all receptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
6
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
191 624
OM-4405 Page 32
SECTION 8 – MAINTENANCE & TROUBLESHOOTING
8-1. Maintenance Label
OM-4405 Page 33
8-2. Routine Maintenance
Note
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Stop engine before maintaining.
Recycle engine
fluids.
See also Engine Manual and Mainte-
nance Label. Service unit more often if
used in severe conditions.
*
To be done by Factory Authorized
Service Agent.
8h
Coolant
Full
Check Fluid
Levels. See
Section 4-7.
OIL
Full
Wipe
Up
Spills.
50 h
Clean Air Filter.
See Section 8-4.
1/2 in.
(13 mm)
Check Belt
Tension.
Clean And
Tighten
Weld
Terminals.
100 h
Change Oil
Filter. See
Section 8-8.
Change Oil. See
Section 8-8.
Clean And
Tighten
Battery
Connections.
Replace fuel
filter. See
Section 8-8.
Check air cleaner hoses
for cracks and loose
clamps.
250 h
Check And
Clean Spark
Arrestor. See
Section 8-3.
Check
Spark
Plugs.
Replace
Unreadable
Labels.
OM-4405 Page 34
500 h
Repair Or
Replace
Damaged
Cables.
Check
Valve
Clearance.*
1000 h
Blow Out Or
Vacuum Inside.
During Heavy
Service,
Clean Monthly.
OR
FUEL
SLUDGE
Drain Sludge
From Fuel
Tank. See
Section 8-8.
Service Welding Generator
Brushes And Slip Rings. Service
More Often In Dirty Conditions.*
8-3. Inspecting And Cleaning Optional Spark Arrestor Muffler
Stop engine and let cool.
1
Spark Arrestor Muffler
2
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3
Exhaust Pipe
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
3
2
1
Stop engine and let cool.
Reinstall cleanout plug.
Tools Needed:
3/8 in
802 729 / Ref. 201 841
OM-4405 Page 35
8-4. Servicing Air Cleaner
Stop engine.
1
2
3
Do not run engine without air
cleaner or with dirty element. Engine damage caused by using a
damaged element is not covered
by the warranty.
4
The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
5
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
Keep nozzle
2 in (51 mm)
from element.
1
Housing
2
Safety Element (Optional)
3
Primary Element
4
Dust Cap
5
Dust Ejector
To clean air filter:
Blow
Inspect
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 – 153 929-B / 153 585 / Ref. S-0698-B
OM-4405 Page 36
8-5. Adjusting Engine Weld/Power Speed
Stop engine and let cool.
Governor
Engine Speed
(No Load)
sensitivity may require adjustment if engine
speed is adjusted (see Section
8-7).
RPM (Hz)
Engine speed is factory set and
should not require adjustment. After tuning engine, check engine
speed with tachometer or frequency meter. See table for proper no
load speed. If necessary, adjust
speed as follows:
1850 (61.7)
Maximum
Weld/Power
Start engine and run until warm.
7
11
On CC Models, place Stick/TIG
switch in Stick position.
10
9
1/16 in
(1.6 mm)
8
6
On CC/CV models, turn Process/
Contactor switch to Stick – Electrode Hot position.
1 Socket Nut
2
Governor Linkage Rod
3
Lock Nut
4
Socket
5
Governor Arm
Rod length should be 3-1/4 in (83
mm) between lock nuts. To adjust,
remove socket from arm and loosen lock nut. Turn socket to adjust
length. Tighten nut and reattach
socket to arm.
If linkage binds, loosen socket
nuts and turn sockets until linkage works smoothly. Tighten
nuts.
1
3-1/4 in
(83 mm)
4
6
Carburetor
7
Throttle Stop Plate
8
Throttle Stop
Clearance between plate and stop
should be 1/16 in (1.6 mm). To adjust clearance, proceed as follows:
3
2
5
9
Linkage Pivot Arm
10 Linkage Socket
11 Lock Nut
Remove socket at arm and loosen
lock nut. Turn socket to adjust
clearance. Reattach socket and
tighten nut.
13
12
Start engine and run until warm.
Turn Engine Control switch to Run
position.
12 Governor Speed Screw
13 Lock Nut
Loosen nut. Turn screw until engine
runs at weld/power speed.
Stop engine.
Close door.
Tools Needed:
3/8, 7/16 in
802 731 / 802 780 / Ref. 801 179 / Ref. 800 161
OM-4405 Page 37
8-6. Adjusting Engine Idle Speed
Stop engine and let cool.
Engine idle speed is factory set and
normally should not require adjustment. After tuning engine, check
engine speed with tachometer or
frequency meter. See table for
proper no load speed. If necessary,
adjust idle speed as follows:
Engine Speed
(No Load)
1850 rpm max
(61.6 Hz)
Start engine and run until warm.
1250 rpm
(41.6 Hz)
On CC Models, place Stick/TIG
switch in Stick position.
2
On CC/CV models, turn Process/
Contactor switch to Stick – Electrode Hot position.
5
1
Solenoid Bracket Screws
2
Throttle Arm
3
Idle Speed Screw
4
Throttle Stop
Loosen bracket screws and move
arm so screw touches stop. Do not
release arm. Turn idle speed screw
to obtain 550 rpm.
5
1
6
7
3
Idle Mixture Screw
Turn mixture screw counterclockwise until engine falters, then turn
screw clockwise until engine runs
smoothly.
Turn idle speed screw to obtain
1250 rpm.
6
Solenoid
7
Plunger
Slide solenoid inside bracket so
plunger bottoms in solenoid. If necessary, shim solenoid/bracket to
prevent linkage from binding. Do
not readjust idle speed screw when
adjusting solenoid.
4
Tighten bracket screws. Release
throttle arm. Recheck idle speed
and readjust if necessary.
Stop engine.
Close door.
Tools Needed:
1/4 in
802 731 / Ref. 115 155-A
OM-4405 Page 38
8-7. Adjusting Governor Sensitivity
Governor
sensitivity may require readjustment if weld
speed is adjusted. Weld speed
must be readjusted if sensitivity
is adjusted.
3
2
1
Be sure carburetor and linkages are adjusted properly before adjusting sensitivity.
Start engine. Apply and remove
load.
1
Locking Nuts
2
Sensitivity Adjustment Screw
3
Governor Spring
If engine is slow to pick up load or
rpm drops under load, adjust spring
tension as follows:
Loosen top nut and tighten bottom
nut to move screw down. Tighten
nuts.
If engine hunts with or without load,
adjust spring tension as follows:
Loosen bottom nut and tighten top
nut to move screw up. Tighten nuts.
Stop engine.
Close door.
Tools Needed:
1/2 in
802 780 / Ref. 115 155-A
Notes
OM-4405 Page 39
8-8. Servicing Fuel And Lubrication Systems
1
3
2
6
5
4
Tools Needed:
802 731 / Ref. 801 434
Stop engine and let cool.
After servicing, start engine and
check for fuel leaks. Stop engine,
tighten connections as necessary,
and wipe up spilled fuel.
1
Oil Filter
2
3
Oil Drain Valve And Hose
Oil Fill Cap/Dipstick
4
Fuel Tank Sludge Drain Valve
maintenance label for oil/filter change information.
to open sludge drain valve. Close valve
when sludge has drained. Remove hose.
To drain sludge from fuel tank:
Close door.
Beware of fire. Do not smoke and
keep sparks and flames away from
drained fuel. Dispose of drained fuel
in an environmentally-safe manner.
Do not leave unit unattended while
draining fuel tank.
To replace fuel filter:
To change oil and filter:
Properly lift unit and secure in a level
position. Use adequate blocks or
stands to support unit while draining fuel tank.
Route oil drain valve and hose through hole
in base. See engine manual and engine
Attach 1/2 ID hose to drain valve. Put metal
container under drain, and use screwdriver
OM-4405 Page 40
5
Fuel Line
6
Fuel Filter
Remove clamps and filter. Install new filter
and clamps. Inspect fuel lines and replace
if cracked or worn. Wipe up any spilled fuel.
Start engine and check for leaks.
Stop engine, tighten connections as
necessary, and wipe up spilled fuel.
Close door.
8-9. Overload Protection
Stop engine.
When a circuit breaker or fuse
opens, it usually indicates a
more serious problem exists.
Contact Factory Authorized
Service Agent.
1
2
Fuse F1
Fuse F2
F1 and F2 protect the stator exciter
winding from overload. If F1 opens,
weld and auxiliary power is low or
stops entirely. If F2 opens, weld output is low or stops entirely. 4 kVA/
kW auxiliary power is still available.
2
1
3
4
8
7
6
Circuit Breaker CB4 (Not
Shown)
Circuit Breaker CB5
(CC/CV Models Only)
5
Circuit Breaker CB10 (Not
Shown)
6
Circuit Breaker CB11
7
Circuit Breaker CB12
8
Circuit Breaker CB13
CB4 protects the welding arc drive
(dig) circuit. If CB4 opens, electrode may stick to the workpiece more
frequently during low voltage (short
arc length) conditions. CB4 automatically resets when the fault is
corrected.
4
CB5 protects the 24 volt ac output
to remote receptacle RC14, and 24
volt output to field current regulator
board PC1 (CC/CV models only). If
CB5 opens, weld output and 24 volt
output to RC14 stops. On units with
optional auxiliary power plant, auxiliary power output at receptacle
RC5 also stops if CB5 opens.
CB10 protects the engine battery
circuit. If CB10 opens, the engine
will not crank. CB10 automatically
resets when the fault is corrected.
CB11 protects the engine wiring
harness. On CC models, if CB11
opens the max OCV circuit does
not work and open circuit voltage is
variable at all times (see max OCV
note under Weld Controls in Section 5-2). If CB11 opens on CV models, weld output stops (auxiliary
power is still available).
CB12 protects the field flashing circuit. If CB12 opens, the generator
may not excite at start-up and weld
and auxiliary power output may not
be available.
CB13 protects the engine shutdown circuit. If CB13 opens, the engine cranks but does not start.
Press button to reset breaker.
802 729 / Ref. 802 789
OM-4405 Page 41
8-10. Diagnosing Causes Of Engine Fault Shutdowns
Use the front panel engine lights to
help determine the cause of an automatic engine shutdown.
Correct the cause of the shut-
Pre-Start Diagnostic Checks
down before operating the
welding generator.
This unit does not have a battery charging fault shutdown.
The engine continues to run if
the Battery Charging Light
goes on.
Turn Engine Control Switch To Run/Idle
Position While Pressing Magnetic Shutdown Switch.
Normal Condition:
Oil Pressure Light On;
Battery Charging, Fuel, And Temperature Lights Off.
If Oil Pressure Light Is Off, See Factory Authorized Service Agent.
If Battery Charging Light Is On, Have Factory Authorized Service Agent
Check Alternator.
If Temperature Light Is On, Correct Cause Of Overheating
(See Engine Manual).
If Engine Is Okay, See Factory Authorized Service Agent.
If Fuel Light Is On, Check Fuel Level.
If Fault Continues, See Factory Authorized Service Agent.
Diagnostic Checks While Running
20s
Start Engine (With No Load Applied).
Continue Pressing Shutdown Switch
Until Engine Lights Go Off.
Normal Condition:
Engine Lights Go Off As Engine Reaches
Normal Operating Condition.
Lights That Stay On After 20 Sec. Indicate
Fault Condition.
Stop Engine And Correct Fault (See Above) If
Fault Continues, See Factory Authorized Service Agent.
Ref. 201 841
OM-4405 Page 42
8-11. Troubleshooting
A. Welding – CC Models
Trouble
Remedy
No weld output; auxiliary power output Check position of Ampere Range switch.
okay.
Check position of optional polarity switch.
Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
control to Remote Amperage Adjust receptacle RC13 (see Sections 4-10 and 5-1).
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 4-10).
Check fuse F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check integrated rectifier SR2 and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
No weld output or auxiliary power output. Disconnect equipment from auxiliary power receptacles during start-up.
Check fuses F1 and F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (see Section 8-9).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output.
Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
High weld output.
Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent check OCV control circuit.
Low weld output.
Check engine speed, and adjust if necessary.
Check fuses F1 and F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 8-9).
frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.
length) conditions.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
Maximum weld output only in each Have Factory Authorized Service Agent check control relay CR7.
ampere range (with Stick/TIG Selection
switch in Stick position).
No remote fine amperage control.
Place Amperage Adjust switch in correct position.
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 4-10).
Reset circuit breaker CB11 (see Section 8-9). Have Factory Authorized Service Agent check control relay
CR7.
Repair or replace remote control device.
Have Factory Authorized Service Agent check OCV control circuit.
OM-4405 Page 43
B. Welding – CC/CV Models
Trouble
Remedy
No weld output; auxiliary power output Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and
okay.
connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 4-11 and 6-1).
Check position of Ampere Range switch.
Check position of optional polarity switch.
Reset circuit breaker CB11 (see Section 8-9).
Reset circuit breaker CB5 (see Section 8-9). Check for faulty remote device connected to RC14.
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).
Have Factory Authorized Service Agent check connector board PC6 and connections.
Check fuse F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check
brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor.
No weld output or auxiliary power output. Disconnect equipment from auxiliary power receptacles during start-up.
Check fuses F1 and F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output.
Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
High weld output.
Check position of Ampere Range switch and Voltage/Amperage Adjust control.
Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent check field current regulator board PC1.
Voltage/Amperage control does not Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere
work when welding in Stick mode.
Range switch in highest range.
Low weld output.
Check engine speed, and adjust if necessary.
Check fuses F1 and F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 8-9).
frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.
length) conditions.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position.
control.
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).
Repair or replace remote control device.
Constant speed wire feeder does not Reset circuit breaker CB5 (see Section 8-9).
work.
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).
Check voltage requirements of wire feeder. 115 volt output not available through Remote 14 receptacle (see Section 4-11).
Repair or replace wire feeder.
Low CV weld output.
Set Ampere Range switch to highest range.
Min or max CV weld output only.
Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.
Repair or replace remote control device.
Have Factory Authorized Service Agent check field current regulator board PC1.
OM-4405 Page 44
C. Standard Auxiliary Power
Trouble
Remedy
No auxiliary power output; weld output Reset receptacle circuit breakers.
okay.
No auxiliary power or weld output.
Disconnect equipment from auxiliary power receptacles during start-up.
Check fuses F1 and F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, and the rotor.
Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (CC models) or field
current regulator board PC1 (CC/CV models) (see Section 8-9).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output
receptacles.
at
auxiliary
power Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent adjust auxiliary power field current resistor R3.
Low output
receptacles.
at
auxiliary
power Check engine speed, and adjust if necessary.
Check fuse F1, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check integrated rectifier SR1, resistor R3, and capacitor C9.
D. Optional Auxiliary Power Plant
Trouble
No or low output at optional auxiliary
power plant/receptacle RC5
(CC/CV models only).
Remedy
Place Process/Contactor switch in Electrode Hot - Stick position (see Section 6-3).
Reset circuit breaker CB7 (see Section 7-2).
Reset circuit breaker CB5 (see Section 8-9).
Check engine weld/power speed, and adjust if necessary (see Section 8-5).
Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
PC1.
High output at optional auxiliary power
plant/receptacle RC5 (CC/CV models
only).
Check engine weld/power speed, and adjust if necessary (see Section 8-5).
Have Factory Authorized Service Agent check field current regulator board PC1.
Erratic output at optional auxiliary power Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
plant/receptacle RC5 (CC/CV models PC1.
only).
E. Engine
Trouble
Engine will not crank.
Remedy
Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8-9).
Have Factory Authorized Service Agent check engine wiring harness and components.
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check Engine Control switch S1.
OM-4405 Page 45
Trouble
Engine cranks but does not start.
Remedy
Press Magnetic Shutdown switch MS1 when starting engine.
Check fuel level.
Reset circuit breaker CB13 (see Section 8-9). Have Factory Authorized Service Agent check enginewiring harness and components.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check control relay CR2, and fuel solenoid FS1.
Engine starts, but stops when Magnetic When starting engine, continue holding Magnetic Shutdown switch until after engine indicator lights go
Shutdown switch is released.
out.
Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high (see Sections 4-7 and 8-10).
Engine hard to start in cold weather.
Use starting Aid (Engine Choke control, see Section 5-1 ).
Keep battery in good condition. Store battery in warm area off cold surface.
Use correct grade oil for cold weather (see Section 8-1).
Engine suddenly stops.
Check fuel, oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low,
or coolant temperature is too high (see Sections 4-7 and 8-10).
See engine manual.
Engine slowly stopped and cannot be
restarted.
Check fuel level.
Check engine air and fuel filters (see Section 8-8).
Check engine wiring harness connections.
See engine manual.
Battery discharges between uses.
Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine idles, but does not come up to
weld speed.
Have Factory Authorized Service Agent check idle module PC7, current transformer CT1, and throttle
solenoid TS1.
Check for obstructed throttle solenoid and linkage.
Engine does not run at idle speed.
CC models: place Stick/TIG Selection switch in Stick position.
CC/CV models: place Process/Contactor switch in any position but Remote-TIG.
Check for obstructed throttle solenoid and linkage.
Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.
OM-4405 Page 46
Notes
OM-4405 Page 47
SECTION 9 – ELECTRICAL DIAGRAMS
Figure 9-1. Circuit Diagram For CC Welding Generator
OM-4405 Page 48
201 991-A
OM-4405 Page 49
Figure 9-2. Circuit Diagram For CC/CV Welding Generator
OM-4405 Page 50
201 992-A
OM-4405 Page 51
SECTION 10 – AUXILIARY POWER GUIDELINES
10-1. Selecting Equipment
1
2
3
Auxiliary Power Receptacles
– Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577
10-2. Grounding Generator To Truck Or Trailer Frame
1
2
3
4
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
3
1
4
GND/PE
OR
2
2
Electrically bond generator
frame to vehicle frame by
metal-to-metal contact.
S-0854
OM-4405 Page 52
10-3. Grounding When Supplying Building Systems
1
1
2
2
GND/PE
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Use ground device as stated
in electrical codes.
2
3
ST-800 576-B
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-4405 Page 53
10-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
10-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
OM-4405 Page 54
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
10-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
OM-4405 Page 55
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-4405 Page 56
10-10. Typical Connections To Supply Standby Power
1
2
3
Obtain and install correct switch.
Switch rating must be same as or
greater than the branch overcurrent
protection.
Customer-supplied equipment is required if
generator is to supply standby power during
emergencies or power outages.
4
1
240 V
6
Neutral
120 V
2
Extension Cord
Select as shown in Section 10-11.
120 V
3
Generator Connections
Connect terminals or plug of adequate amperage capacity to cord.
Follow all applicable codes and
safety practices.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltage and frequency.
240 V
120 V
Load
Circuit Breakers or Fused
Disconnect Switch
Obtain and install correct switch.
5
120/240 Volt
60 Hz
Three-Wire
Service
Power Company Service
Meter
Main and Branch Overcurrent
Protection
Double-Pole, Double-Throw
Transfer Switch
120 V
7
Load Connections
4
7
CB
Item 4 is not necessary if circuit
protection is already present in
welding generator auxiliary
power output circuit.
or
F1
6
5
240 V
120/240 Volt
Single-Phase
Three-Wire
Generator Output
Connection
120 V
120 V
Ground
S-0405-A
OM-4405 Page 57
10-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-4405 Page 58
6
Notes
OM-4405 Page 59
SECTION 11 – PARTS LIST
Hardware is common and
not available unless listed.
15
16
17
18
3
2
14
13
1
19
20
12
4
21
11
5 6
22
9
10
8
7
107
106
12
100 (Fig. 11–7)
24
23
93
101
99
25
46
105
98 (FIG. 11–2 OR 11–3)
92
97
94
96 (CC ONLY)
103
102
95
104 (FIG. 11–4 OR 11–5)
Figure 11-1. Main Assembly
OM-4405 Page 60
32
58
57
55
31
33
56
28
59
30
29
27
54
52
26
61
51
34
60
53
62
108
50
35
63
64
48
47
84
77
78
79
49
80
81
82
85
90
39
36
66
67
83
91 (SEE FIG. 11–6)
89
69
65
88 87
68
70
75
71
72
86
40
41
37
38
42
76
43
74
73
44
45
46
802 789
OM-4405 Page 61
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 189 824
. . . 2 . . . . . . . . . . . . . 191 623
. . . 3 . . . . . . . . . . . . +189 828
. . . 4 . . . . . Z1 . . . CC202 151
. . . 4 . . . . . Z1 . . . CV201 514
. . . 5 . . . . . 1T . . . . 038 621
. . . . . . . . . . . . . . . . . . . 038 620
. . . 6 . . . . . . . . . . . . . 081 499
. . . 7 . . . . . . . . . . . . . 201 701
. . . 8 . . SR4, SR5 . 035 704
. . . 9 . . . . CB4 . . . 045 061
. . . 10 . . . . . . . . . . . . . 201 697
. . . 11 . . . . . T1 . . . . 201 613
. . . 12 . . . . . . . . . . . . . 173 352
. . . 13 . . . . . . . . . . . . . 189 708
. . . 14 . . . . . . . . . . . . . 191 307
. . . 15 . . . . . . . . . . . . . 200 968
. . . 16 . . . . . . . . . . . . . 010 863
. . . 17 . . . . . . . . . . . . . 189 763
. . . 18 . . . . . . . . . . . . . 189 764
. . . . . . . . . . . . . . . . . . . *192 938
. . . . . . . . . . . . . . . . . *♦192 939
. . . 19 . . . . . . . . . . . . . 198 457
. . . 20 . . . . . . . . . . . . . 200 969
. . . 21 . . . . . . . . . . . . . 189 464
. . . . . . . . . . . . . . . . . . . 173 909
. . . 22 . . . . . . . . . . . . . 201 658
. . . 23 . . . . . . . . . . . . +200 999
. . . 24 . . . . . . . . . . . . . 196 220
. . . 25 . . . . . . . . . . . . . 192 362
. . . 26 . . . . . . . . . . . . +200 995
. . . 27 . . . . . . . . . . . . . 189 052
. . . 28 . . . . . . . . . . . . . 190 198
. . . 29 . . . . . . . . . . . . . 192 042
. . . 30 . . . . . . . . . . . . . 108 487
. . . 31 . . . . . . . . . . . . . 010 875
. . . 32 . . . . . . . . . . . . . 105 740
. . . 33 . . . . . . . . . . . . . 201 851
. . . 34 . . . . . . . . . . . . . 176 230
. . . 35 . . . . . . . . . . . . . 191 354
. . . 36 . . . . . . . . . . . . . 189 245
. . . 37 . . . . . . . . . . . . . 124 253
. . . . . . . . . . . . . . . . . . . 084 173
. . . 38 . . . . . . . . . . . . . 189 912
. . . 39 . . . . . . . . . . . . . 189 909
. . . 40 . . . . . . . . . . . . . 201 025
. . . 41 . . . . . . . . . . . . . 189 913
. . . 42 . . . . . . . . . . . . . 190 142
. . . 43 . . . . . . . . . . . . . 189 910
. . . 44 . . . . . . . . . . . . . 189 908
. . . 45 . . . . . . . . . . . . . 181 572
. . . 46 . . . . . . . . . . . . . 191 446
. . . 47 . . . . . . . . . . . . . 013 367
. . . 48 . . . . . . . . . . . . . 200 984
. . . . . . . . . . . . . . . . . . . *025 474
. . . . . . . . . . . . . . . . . . . *025 473
. . . . . . . . . . . . . . . . . . . 201 141
. . . . . . . . . . . . . . . . . . . *201 142
OM-4405 Page 62
. . PANEL, gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning all panels must be in place while running . . . . . . . . . . . . .
. . PANEL, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 30A 4 pole frict term str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACE, front to center upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, integ bridge 40. amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT BREAKER, auto reset 24vdc 7 amp . . . . . . . . . . . . . . . . . . . . . . .
. . PAN, reactor and rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER w/bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . .
. . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, elbow air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, hose 1.125 – 3.000 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBE, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, sae .312 id x .560 od x 24.000 (order by ft) . . . . . . . . . . . . . . . . . .
. . UPRIGHT, center assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, hold down fuel tank rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg nyl 1/2 conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, plastic neck filler fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAP, tank screw-on 3.500 in w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, use gasoline fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, muffler 2.000 dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIPE, muffler exhaust engine 1.925 inlet/outlet . . . . . . . . . . . . . . . . . . . . . .
. . COVER, radiator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning hot exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SUPPORT, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TANK, fuel 23gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CLAMP, hose .460 – .545clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, stl barbed elbow w/.047 in orf zinc pld . . . . . . . . . . . . . . . . . . .
. . . . FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc . . . . . . . . . . . . . . .
. . . . CAP, fuel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, stl barbed elbow zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SENDER, fuel gauge 9.7500 deep tank . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc . . . . . . . . . . . . .
. . . . VALVE, drain fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . . .
. . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENGINE, Wis-Con gasoline TM-20 (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . SWITCH, thermo temp 240 make 230 open . . . . . . . . . . . . . . . . . . . . . .
. . . . SWITCH, pressure oil 8 psi brake or make . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FTG, adapter oil drain 1/2-20 male x 3/8 npt female . . . . . . . . . . . . . . . .
. . . . BELT, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . . . 172 725 . . BOOT, starter eyelet terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *114 559 . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 49 . . . . . . . . . . . . . *066 113 . . FILTER, inline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . . 200 966 . . HOSE, radiator upper Wis-Con TM-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 51 . . . . . . . . . . . . +202 052 . . GUARD, fan (left side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 52 . . . . . . . . . . . . . 147 923 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 53 . . . . . . . . . . . . . 201 982 . . RADIATOR, w/shroud and 7lb cap 3 row core . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 605 982 . . . . CAP, radiator pressure 7 lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 54 . . . . . . . . . . . . . 201 749 . . UPRIGHT, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 55 . . . . . . . . . . . . . 190 206 . . CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng . . . . . . . . . . . . .
. . . 56 . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . .
. . . 57 . . . . . . . . . . . . . 190 207 . . CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng . . . . . . . . . . . . .
. . . 58 . . . . . . . . . . . . . 203 430 . . BRACKET, battery holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 59 . . . . . . . . . . . . . 190 897 . . BATTERY, stor 12V 650crk 110rsv gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 60 . . . . . . . . . . . . . 201 006 . . BOLT, j stl .312–18 x 8.500 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 61 . . . . . . . . . . . . +201 183 . . COVER, battery access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 62 . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 63 . . . . . . . . . . . . . 201 996 . . LABEL, warning do not operate with guard missing . . . . . . . . . . . . . . . . . .
. . . 64 . . . . . . . . . . . . . 200 967 . . HOSE, radiator lower Wis-Con TM-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 65 . . . . . . . . . . . . +200 990 . . GUARD, fan (right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 66 . . . . . . . . . . . . . 190 992 . . KEEPER, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 67 . . . . . . . . . . . . . 190 076 . . CHANNEL, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 68 . . . . . . . . . . . . . 199 592 . . LATCH, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 69 . . . . . . . . . . . . . 201 031 . . LABEL, gasoline engine maintenance Wis-Con TM-20 . . . . . . . . . . . . . . .
. . . 70 . . . . . . . . . . . . +200 989 . . DOOR, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 71 . . . . . . . . . . . . . 189 975 . . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 72 . . . . . . . . . . . . . 190 190 . . TANK, coolant recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 73 . . . . . . . . . . . . . 201 591 . . STOP, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 74 . . . . . . . . . . . . . 189 826 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 75 . . . . . . . . . . . . . 191 626 . . BUMPER, door engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 76 . . . . . . . . . . . . . 189 827 . . PANEL, gen RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 77 . . . . . . . . . . . . . 199 849 . . SCREW, 625-11 x 4.00hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 78 . . . . . . . . . . . . . 071 731 . . WASHER, flat .656 ID x 2.250 OD x .187T stl pld . . . . . . . . . . . . . . . . . . . .
. . . 79 . . . . . . . . . . . . . 200 985 . . BRACKET, mtg engine Wis-Con TM-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 80 . . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 81 . . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 82 . . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 . . . . . . . . . . . . . . . . . .
. . . 83 . . . . . . . . . . . . . 135 205 . . NUT, 625-11 .94hex .76H stl pld elastic stop nut . . . . . . . . . . . . . . . . . . . . .
. . . 84 . . . . . . . . . . . . . . 190757 . . SOLENOID ASSY (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 113658 . . . . LINKAGE, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 115857 . . . . BRACKET, mtg solenoid idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 005373 . . . . SOLENOID, 14vdc .84 amp pull type cont . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 010837 . . . . PIN, spring cs .093 x .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 199 505 . . HOSE, oil drain assy 32 in (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 85 . . . . . . . . . . . . . 165 271 . . . . VALVE, oil drain 3/8-18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 86 . . . . . . . . . . . . . 176 529 . . . . FITTING, hose brs barbed fem 1/2tbg x 3/8NPT . . . . . . . . . . . . . . . . . . .
. . . 87 . . . . . . . . . . . . . . 113 854 . . . . HOSE, SAE .500 ID x .780 OD xc oil (order by ft) . . . . . . . . . . . . . . . . . .
. . . 88 . . . . . . . . . . . . . 197 448 . . FITTING, hose brs barbed elbow m 1/2 tbg x 3/8 npt . . . . . . . . . . . . . . . . .
. . . 89 . . . . . . . . . . . . . 201 141 . . FITTING, engine adapter oil drain 12-20 x 3/8 npt female . . . . . . . . . . . . .
. . . 90 . . . . . . . . . . . . . 201 362 . . WASHER, oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 91 . . . . . . . . . . . Figure 11-6 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 92 . . . . . . . . . . . . . 191 897 . . BRACKET, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 93 . . . . . . . . . . . . . 191 512 . . BRACKET, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 94 . . . . . . . . . . . . . 190 250 . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 95 . . . . . . . . . . . . . 190 179 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 96 . . . . . R2 . . . CC189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . .
. . . 97 . . . . . R3 . . . . 189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . .
. . . 98 . . . . . . Figure 11-2, Figure 11-3 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4
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4
4
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1
1
1
1
1
1
1
3ft
1
1
1
1
4
1
2
1
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1
1
OM-4405 Page 63
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (Continued)
. . . 99 . . . . . . . . . . . . . 189 731 . . FIREWALL, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . Figure 11-7 . . MAIN RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . 191 448 . . TOP, cover front upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . +201 750 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . 182 761 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . Figure 11-4, Figure 11-5 PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . . 202130 . . XFMR, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . CV193 453 . . BRACKET, mtg box fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . PC1 . . CV189 143 . . MODULE, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . +147 923 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 190 058 . . NUT, .250-20 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . 049 525 . . NUT, 312-18 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . 202 022 . . KIT, label (includes safety and informational labels) . . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 202 022.
*Recommended Spare Parts.
C
C CC models only.
C
V CC/CV models only.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement
Parts. Model and serial number required when ordering parts from your local distributor.
4
14
18
6
3
17
8
7
10
2
20
1
9
15
11
16
13
12
19
5
Figure 11-2. Control Box Assembly – CC Models
OM-4405 Page 64
802 551-A
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Control Box Assembly – CC Models (Figure 11-1 Item 98)
. . . 1 . . . F1, F2 . . *085 874 . . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . 201 077 . . CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 201 078 . . CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 201 079 . . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . C12 . . . 191 944 . . CAPACITOR, polyp met film 10. uf 250 vac 10% . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 681 . . HARNESS, control box, weld control (consisting of) . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . CR7 . . . 188 636 . . . . RELAY, OCV control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . D1/C1 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . SR1, SR2 . 035 704 . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . CR5 . . . 090 104 . . . . RELAY, encl 12VDC SPST 30A/15VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH, tgl spdt 15a 125vac on–none–on spd term chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 11-4) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . . 011 622 . . . . SWITCH, tgl 3pdt 15a 125vac on–none–on spd term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 11-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . . . . . 1
. . . . . . . . . . RC3 . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . . . . . 1
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 177 859 . . . . CONN, body 5 terminal (to engine control switch S1) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 150 316 . . . . CONN, rect univ 039 6p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . 092 670 . . . . CONN, rect univ 084 3p/s 1row plug cable lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 CB11, 12, 13 139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . 190 260 . . HARNESS, unit weld control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 158465 . . . . CONN, rect univ 084 12p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187654 . . . . SEAL, wire univ 12p/s 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114063 . . . . CONN, rect univ 084 4p/s 1row plug cable lkg . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192309 . . . . CLIP, snap in .630 bundle .250 hole .248 thk . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . C9 . . . . . 087 110 . . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . R6 . . . . 141 424 . . RESISTOR, ww fxd 30 w 25 ohm faston te . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . PC7 . . . . 195706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CR4 . . . . 113247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . . 1
. . . 17 . . . . CR6 . . . . 090104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
. . . 18 CR1, CR2, CR3 090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . 201 357 . . HARNESS, engine control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . D8/C8 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . CB10 . . . 190 374 . . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . . 1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4405 Page 65
4
16
3
15
17
11
18
2
1
10
13
14
6
12
7
8
9
5
802 360
Figure 11-3. Control Box Assembly – CC/CV Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Control Box Assembly – CC/CV Models (Figure 11-1 Item 98)
. . . 1 . . . F1, F2 . . *085 874 . . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 201 077 . . CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . 201 078 . . CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . 201 079 . . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . 134 201 . . STAND-OFF, support pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . PC9 . . . 192 224 . . CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . C9 . . . . . 087 110 . . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 201 495 . . HARNESS, control box, cv weld control (consisting of) . . . . . . . . . . . . . . .
. . . 10 . . . . SR1 . . . 035 704 . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . CR5 . . . 090 104 . . . . RELAY, encl 12VDC SPST 30A/15VDC . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC4 . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . . . . .
. . . . . . . . . . RC3 . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . . . . .
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . .
. . . 12 CB11, 12, 13 139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S6 . . . . 193 324 . . . . SWITCH, rotary 6 position gold contacts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 11-5) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH,tgl spdt 15a 125vac on–none–on spd term chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 11-5) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 150 316 . . . . CONN, rect univ 039 6p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 66
2
2
1
1
1
3
1
1
1
1
1
1
1
1
1
3
1
1
1
6
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Control Box Assembly – CC/CV Models (Continued)
. . . . . . . . . . . . . . . . . . . 177 859 . . . . CONN, body 5 terminal (to engine control switch S1) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 193 183 . . . . CONN, rect cinch 18 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 196 602 . . . . PLUG, cavity 18,30 position cinch connector . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 196 603 . . . . SEAL, switch 6 position rotary .250 shaft . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 141 450 . . . . CONN, rect metrmate 10skt 1row plug cable lkg . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . PC7 . . . . 195706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CR4 . . . . 113247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CR6 . . . . 090104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
. . . 16 CR1, CR2, CR3 090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . 201 357 . . HARNESS, engine control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . D8/C8 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . CB10 . . . 190 374 . . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 185 655 . . . . SEAL, wire univ 15P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4405 Page 67
4
Hardware is common and
not available unless listed.
3
5
2
1
6
7
8
9
10
40
39
38
11
12
13
14
15
35
36
34
33
16
32
17
31
37
30
29
28
18
19
21
20
22
27
26
25
24
23
802 799
Figure 11-4. Panel, Front w/Components – CC Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-4. Panel, Front w/Components – CC Models (Figure 11-1 Item 104)
. . . 1 . . . . . . . . . . . . . 201 841 . . PLATE SCREENED, ident control rating; when ordering this item,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, screened (order by model and serial number) . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 201 580 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . S3 . . . . 189 382 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 202 223 . . BUS BAR, idealized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 68
1
1
1
1
2
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-4. Panel, Front w/Components – CC Models (Continued)
. . . 5 . . . . . R1 . . . . 188 635 . . RHEOSTAT, WW 300W 34 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . S6 . . . . . 011 622 . . SWITCH, tgl DPDT 15A 125VAC (included in control box harness,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Figure 11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see Figure 11-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . RC13 . . . 032 897 . . RECEPTACLE, twlk grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . S1 . . . . 176 606 . . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . MS1 . . . 189 698 . . SWITCH, magnetic manual reset low current . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . CB1 . . . 201 083 . . CIRCUIT BREAKER, man reset 2P 20 A, 250VAC . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 201 109 . . HARNESS, auxiliary power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . CB2 . . . 093 996 . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . .
. . . 14 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . .
. . . 15 . . . . RC1 . . . 147 632 . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . 190 861 . . LABEL, warning electric shock and moving parts . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . +201 106 . . PANEL, aux pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . 083 030 . . STUD, brs .250–20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . 601 836 . . NUT, 250–20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . 193 260 . . COVER, receptacle 2.250 dia lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . 193 258 . . COVER, receptacle GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . 193 143 . . BOOT, magnetic shutdown switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . 200 993 . . CONTROL, push-pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . 119 014 . . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . PL1 . . . 191 241 . . LED, red 12V 4 ind lights panel mtg round . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . FUEL . . . 192 265 . . GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . HM . . . . . 118 058 . . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . . 148 723 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 024 103 . . BLANK, snap–in nyl .750 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3
1
1
1
1
1
1
1
1
3
1
1
1
1
1
3
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
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 192 505 or Label Kit 202 022.
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-4405 Page 69
Hardware is common and
4
not available unless listed.
3
5
2
1
6
7
8
9
10
11
56
55
12
54
53
13
14
15
16
50
17
51 49
48
52
47
18
19
46
20
33
45
30
32
21
29
22
23
25
31
28
43
44
24
27
26
34
35
42
36
41
40
39
38
37
802 732
Figure 11-5. Panel, Front w/Components – CC/CV Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-5. Panel, Front w/Components – CC/CV Models (Figure 11-1 Item 104)
. . . 1 . . . . . . . . . . . . . 201 579 . . PLATE SCREENED, ident control; when ordering this item,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, screened (order by model and serial number) . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 201 580 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . S3 . . . . 189 382 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ♦202223 . . BUS BAR, idealized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4405 Page 70
1
1
1
1
2
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-5. Panel, Front w/Components – CC/CV Models (Continued)
. . . 5 . . . . . R1 . . . . . 193 118 . . POT, cp flat 1t 2w 1k ohm linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . S6 . . . . 193 234 . . SWITCH, rotary 6 position gold contacts (included in control box harness,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Figure 11-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see Figure 11-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . PC6 . . . 192 995 . . CIRCUIT CARD ASSY, connector/receptacle . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CB5 . . . 139 266 . . CIRCUIT BREAKER, man reset 1p 15a 250vac frict . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S1 . . . . 176 606 . . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . MS1 . . . 189 698 . . SWITCH, magnetic manual reset low current . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB1 . . . 201 083 . . CIRCUIT BREAKER, man reset 2P 20 A, 250VAC . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 109 . . HARNESS, auxiliary power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB2 . . . 093 996 . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . 1
. . . 15 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . 1
. . . 16 . . . . RC1 . . . 147 632 . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC5 . . ♦182 954 . . RCPT, str 3P4W 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . ♦025 248 . . STAND-OFF, insul .250-20 x 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . ♦604 102 . . CONNECTOR, clamp cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . ♦197 527 . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . ♦197 363 . . TERMINAL, ring tng screw clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 22 . . . . CB7 . . ♦196 780 . . CIRCUIT BREAKER, man reset 3p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . +201 106 . . PANEL, auxiliary power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . +♦201 107 . . PANEL, auxiliary power (full kVA option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . ♦196 781 . . BOOT, circuit breaker 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . ♦197 508 . . PLUG, protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . ♦077 440 . . BUSHING, conduit 1 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . 601 836 . . NUT, 250–20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 28 . . . . . . . . . . . . ♦197 291 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 083 030 . . STUD, brs .250–20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CT2 . . ♦197 433 . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 190 861 . . LABEL, warning electric shock and moving parts . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . ♦197 399 . . LABEL, warning 3 ph auxiliary power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 193 260 . . COVER, receptacle 2.250 dia lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 193 258 . . COVER, receptacle GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . PC4, PC5 . 189 744 . . CIRCUIT CARD ASSEMBLY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 37 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . 134 201 . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 39 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 40 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 41 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . 193 143 . . BOOT, magnetic shutdown switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . 200 993 . . CONTROL, push-pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 119 014 . . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . 170 391 . . CONN, circ ms protective cap size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . PL1 . . . 191 241 . . LED, red 12V 4 ind lights panel mtg round . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . FUEL . . . 192 265 . . GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . HM . . . . . 118 058 . . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4405 Page 71
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-5. Panel, Front w/Components – CC/CV Models (Continued)
. . . 53 . . . . . . . . . . . . . 097 922
. . . 54 . . . . . . . . . . . . . 189 161
. . . 55 . . . . . . . . . . . . . 010 647
. . . 56 . . . . . . . . . . . . . 097 924
. . . . . . . . . . . . . . . . . . . 193 158
. . . . . . . . . . PLG6 . . . . 114 063
. . . . . . . . . . PLG8 . . . 193 184
. . . . . . . . . PLG13 . . 147 992
. . . . . . . . . . PLG3 . . . 158 465
. . . . . . . . . . . . . . . . . . . 088 731
. . . . . . . . . . . . . . . . . . . 135 873
. . . . . . . . . . . . . . . . . . . 187 654
. . . . . . . . . . . . . . . . . . . 024 103
. . . . . . . . . . . . . . . . . . . 120 304
+
. . KNOB, pointer .875 dia x .250 ID w/set screws plstc . . . . . . . . . . . . . . . . .
. . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc . . . . . . . . . . . . . . . . .
. . HARNESS, unit weld control – CV (consisting of) . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg . . . . . . . . . . . . . .
. . . . CONNECTOR, rect cinch 30 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect univ 039 10p/s 2 row plug cable . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect univ 084 12p/s 3 row plug cable . . . . . . . . . . . . . . . .
. . . . BUSHING, snap-in nyl .375 ID x .500 mtg hole . . . . . . . . . . . . . . . . . . . .
. . . . CLIP, conduit convoluted 1/2 in mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SEAL, wire univ 12p/s 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLANK, snap-in nyl .750 mtg hole blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLANK, snap–in nyl .250 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
2
1
1
2
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 202 022.
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.
22
17
15
16
11
14
10
12
23
18
19
13
9
20
21
8
7
6
5
3
1
2
24
16
4
25
29
30
27
28
26
31
32
33
28
34
802 800
Figure 11-6. Generator
OM-4405 Page 72
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-6. Generator (Figure 11-1 Item 91)
. . . 1 . . . . . . . . . . . . . 132 053
. . . 2 . . . . . . . . . . . . . 183 387
. . . 3 . . . . . . . . . . . . . . 195 911
. . . 4 . . . . . . . . . . . . . 143 220
. . . 5 . . . . . . . . . . . . . 201 099
. . . 6 . . . . . . . . . . . . +201 110
. . . 6 . . . . . . . . . . . +♦201 089
. . . 7 . . . . . . . . . . . . . 013 367
. . . 8 . . . . . . . . . . . . . 190 197
. . . 9 . . . . . . . . . . . . . 172 674
. . . 10 . . . . . . . . . . . . . 039 207
. . . 11 . . . . . . . . . . . . . 201 098
. . . 12 . . . . . . . . . . . . . 024 617
. . . 13 . . . . . . . . . . . . . 053 390
. . . 14 . . . . . . . . . . . . . 195 547
. . . 15 . . . . . . . . . . . . . 049 026
. . . 16 . . . . . . . . . . . . . 083 883
. . . 17 . . . . . . . . . . . . . 202 301
. . . 18 . . . . . . . . . . . . . 605 231
. . . 19 . . . . . . . . . . . . . 194 512
. . . 20 . . . . . . . . . . . . . 183 387
. . . 21 . . . . . . . . . . . . . 198 631
. . . 22 . . . . . . . . . . . . . 201 139
. . . 23 . . . . . . . . . . . . . 201 140
. . . 24 . . . . . . . . . . . . . 191 579
. . . . . . . . . . . . . . . . . . . 200 991
. . . . . . . . . . . . . . . . . . . 191 580
. . . 25 . . . . . . . . . . . . . 172 555
. . . 26 . . . . . . . . . . . . . 602 159
. . . 27 . . . . . . . . . . . . . 601 950
. . . 28 . . . . . . . . . . . . . . 602 211
. . . 29 . . . . . . . . . . . . . 139 341
. . . 30 . . . . . . . . . . . . . *190 823
. . . 31 . . . . . . . . . . . . . 188 560
. . . 32 . . . . . . . . . . . . . 189 142
. . . 33 . . . . . . . . . . . . . 602 242
. . . 34 . . . . . . . . . . . . . 604 534
. . . . . . . . . . . . . . . . . . . 190 259
. . . . . . . . . . PLG1 . . . 135 134
. . . . . . . . . . . . . . . . . . . 187 651
. . SCREW, .375–16x1.50 hex hd–pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, conical spring .406 ID x .875 OD pltd . . . . . . . . . . . . . . . . . . . . .
. . ENDBELL, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, exciter/aux pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, weld assembly complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, weld assembly complete (full kVA option) . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUARD, generator wire mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPRING, ext .240 OD x .041 wire x 3.500pld . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROTOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RING, rtng ext 1.375 shaft x .050thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BEARING, ball rdl sgl row 1.370 x 2.830 x .6 . . . . . . . . . . . . . . . . . . . . . .
. . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, M10-1.5 x 25hexhd pln 8.8pln . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, lock .402 ID x 0.709 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PLATE, flex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, m10–1.5x 35 hex hd–pln 8.8 pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat 1.250 od x .406id x 7ga thk stl pld . . . . . . . . . . . . . . . . . . .
. . . . WASHER, cone .380idx .860odx.109t stl pld 4000lbs . . . . . . . . . . . . . .
. . . . NUT, m10 hex lock nut stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FLYWHEEL, engine Wis-Con TM-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ADAPTER, engine Wis-Con TM-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, starter hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUARD, starter hole Wis-Con TM-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, starter hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, M10-1.5 x 50hexhd pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, .312–18x .75 hexwhd.66d stl pld slffmg tap–rw . . . . . . . . . . . . .
. . SCREW, .312-18 x 2.00 hexhd pln gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, lock .318 ID x 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRUSHHOLDER ASSEMBLY, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat .375IDx0.875odx.083t stl pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, .312–18x1.25 hex hd–pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . HARNESS, brush (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect univ 084 9P/S 3 row plug cable lkg . . . . . . . . . . . . .
. . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
1
1
1
1
1
2
1
2
1
1
1
1
1
6
10
1
4
4
6
4
1
1
1
1
1
6
6
4
6
4
3
3
1
2
2
1
1
1
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 202 022.
*Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4405 Page 73
Hardware is common and
4
not available unless listed.
3
2
1
5
6
7
8
9
802 279-A
Figure 11-7. Main Rectifier Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-7. Main Rectifier Assembly (Figure 11-1 Item 100)
...................
... 1 .............
... 2 .............
... 3 .............
... 4 .............
. . . 5 . . . . PC3 . . .
... 6 .............
... 7 .............
. . . 8 . D3, D5, D7
. . . 9 . D2, D4, D6
201 747
188 137
188 517
188 135
134 201
201 449
188 136
188 493
037 956
037 957
. . RECTIFIER (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTION BOARD, rectifier AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUS BAR, connection board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ENCLOSURE, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSEMBLY, protection . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . INSULATOR, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HEAT SINK, rectifier al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
3
2
3
1
8
2
3
3
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4405 Page 74
Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts – 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 185 & Spoolmate 250
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 7/00
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
 2001 Miller Electric Mfg. Co.
1/01