Miller BIG BLUE 350 PIPEPRO (CAT) User manual

Miller BIG BLUE 350 PIPEPRO (CAT) User manual
OM-255 254C
2012−06
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
)
)
Big Blue 350 PipePro CAT
)
)
Big Blue 350X PipePro CAT CE
File: Engine Drive
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. CV Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. CC Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Serial Number And Rating Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Arc Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Lift-Arc TIG With Auto-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Operating Optional Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
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3
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6
7
7
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9
10
11
13
13
13
14
14
17
18
18
18
18
19
19
20
20
21
21
22
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22
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24
24
25
26
27
27
28
28
30
30
31
32
33
34
35
36
37
TABLE OF CONTENTS
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. North American Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Export Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. GFCI Receptacle Information, Resetting And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Inspecting And Cleaning Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Maintaining Stainless Steel (Models With Optional Package) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
38
38
39
40
41
41
42
43
44
45
45
46
47
48
48
48
49
52
56
56
57
58
59
66
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Big Blue 350X Pipe Pro
Stock Number
907530
Council Directives:
• 2006/95/EC Low Voltage
• 2004/108/EC Electromagnetic Compatibility
• 2000/14/EC Noise Level of Welding Generators
Standards:
• IEC 60974­1:2005 Arc welding equipment – Part 1: Welding power sources
• IEC 60974­10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
• EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,
arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic
fields (0 Hz – 300Hz)
Signatory:
May 16, 2012
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
257583­A
EUROPEAN COMMUNITY
Manufacturer (Name and Full Address)
Miller Electric Mfg Co.
1635 W Spencer Street
Appleton
Wisconsin 54912−111
United States of America
Report Holder (Name and Full Address)
Miller Electric Mfg Co.
1635 W Spencer Street
Appleton
Wisconsin 54912−111
United States of America
Noise Technical Construction File Ref
NOTIFIED BODY EVALUATION REPORT
No.
GB/1067/0550/04 Issue 9
ISSUING NOTIFIED BODY
AVTECH House, Arkle Avenue
Miller/NTCF/001 Cat Issue 1
Stanley Green Trading Estate
Dated
Handforth, Cheshire,
st
21 July 2004
SK9 3RW, United Kingdom.
Measured Sound Power Level
NTCF Satisfies the Provisions of:
2000/14/EC & 2005/88/EC
SI 2001/1701 & SI 2005/3525
96 dB L WA
Guaranteed Sound Power Level
Sound Power Level Limit
96 dB L WA
96 dB L WA
Description of Equipment
Type of Equipment:
Welding and Power Generator
Category:
Generator
Trade Name:
Miller
Machine Type:
Big Blue 400CX Caterpillar/Perkins
Size of Equipment:
10kW
Conformity Assessment Procedure Followed:
Annex VI Procedure 2 (Directive)
Schedule 9 Section 6 Procedure 2 (Regulations)
Additional Information, if any:
Also covers Big Blue 350X Pipe Pro
VALIDITY
Report Issued:
1st November 2010
Place:
Handforth, United Kingdom
Date of Next Review:
1st November 2013
Stamp:
Signature:
Paul Francis
Form rev. 01/01/2012
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2011−10
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! 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 1-7. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also live
when power is on. In semiautomatic or automatic wire
welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically
live. Incorrectly installed or improperly grounded
equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install, ground, and operate 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.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
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.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
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. Disconnect cable for process not in
use.
SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER stopping engine.
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
FLYING METAL or DIRT 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.
OM-255 254 Page 1
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 local forced ventilation at the
arc to remove welding fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand 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 while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
BUILDUP OF GAS can injure or kill.
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Sparks fly off from the weld.
Wear an approved welding helmet fitted with a proper shade of filter
lenses 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,
glare, and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly off
from the welding arc. The flying sparks, hot workpiece,
and hot equipment can cause fires and burns. Accidental contact of
electrode to metal objects can cause sparks, explosion, overheating,
or fire. Check and be sure the area is safe before doing any welding.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
OM-255 254 Page 2
Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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, sparks, and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is
high.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding process,
be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct compressed 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.
Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Engine Hazards
BATTERY EXPLOSION can injure.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables, battery charging cables (if
applicable), 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 unless the unit has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery.
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
MOVING PARTS can injure.
Keep away from moving parts such as 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 persons remove doors, panels, covers, or
guards 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 doors, panels, covers, or guards 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.
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.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
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.
Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside a home or garage, EVEN IF
doors and windows are open.
Only use OUTSIDE and far away from windows, doors, and
vents.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
1-4. Compressed Air Hazards
COMPRESSED AIR EQUIPMENT can
injure or kill.
Incorrect installation or operation of this unit
could result in equipment failure and personal
injury. Only qualified persons should install, operate, and service this unit according to its
Owner’s Manual, industry standards, and national, state, and local codes.
Do not exceed the rated output or capacity of the compressor or
any equipment in the compressed air system. Design compressed
air system so failure of any component will not put people or property at risk.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s instructions.
Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
Use only components and accessories approved by the manufacturer.
Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
Do not work under or around any equipment that is supported only
by air pressure. Properly support equipment by mechanical
means.
OM-255 254 Page 3
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
COMPRESSED AIR can injure or kill.
Before working on compressed air system,
turn off and lockout/tagout unit, release pressure, and be sure air pressure cannot be accidentally applied.
Relieve pressure before disconnecting or connecting air lines.
Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
Do not direct air stream toward self or others.
Wear protective equipment such as safety glasses, hearing protection, leather gloves, heavy shirt and trousers, high shoes, and
a cap when working on compressed air system.
Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
found.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
If ANY air is injected into the skin or body seek medical help immediately.
BREATHING COMPRESSED AIR can injure or kill.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill
cap.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
HOT PARTS can burn.
Do not touch hot compressor or air system
parts.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or
stopping engine.
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
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.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OM-255 254 Page 4
FLYING SPARKS can injure.
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.
MOVING PARTS can injure.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
BATTERY CHARGING OUTPUT and BATTERY
EXPLOSION can injure.
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.
Battery charging not present on all models.
Always wear a face shield, rubber gloves, and protective
clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables,
battery charging cables (if applicable), 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 unless it has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery.
Have only qualified persons do battery charging work.
If battery is being removed from a vehicle for charging, disconnect negative (−) cable first and connect it last. To prevent an arc,
make sure all accessories are off.
Charge lead-acid batteries only. Do not use battery charger to
supply power to an extra-low-voltage electrical system or to
charge dry cell batteries.
Do not charge a frozen battery.
Do not use damaged charging cables.
Do not charge batteries in a closed area or where ventilation is
restricted.
Do not charge a battery that has loose terminals or one showing
damage such as a cracked case or cover.
Before charging battery, select correct charger voltage to match
battery voltage.
Set battery charging controls to the Off position before connecting to battery. Do not allow battery charging clips to touch each
other.
Keep charging cables away from vehicle hood, door, or moving
parts.
TILTING OF TRAILER can injure.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
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.
WELDING WIRE can injure.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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.
Electromagnetic energy can interfere with
sensitive electronic equipment such as microprocessors, computers, and computer-driven
equipment such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-255 254 Page 5
1-6. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/portgen.pdf).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-8. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures
in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-255 254 Page 6
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
fre_rom_2011−10
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 1-7. 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.
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.
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 à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
Des précautions de sécurité supplémentaires sont requises dans
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas travailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à
l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
1910.147 (voir normes de sécurité).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
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.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chaudes.
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.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
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 métalmétal 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.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
OM-255 254 Page 7
Il reste une TENSION DC NON NÉGLIGEABLE dans les
sources de soudage onduleur UNE FOIS le moteur coupé.
Couper l’alimentation du poste et décharger les condensateurs
d’entrée comme indiqué dans la Section Maintenance avant de
toucher des composants.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher à mains nues les parties chaudes.
Prévoir une période de refroidissement avant
de travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer
des blessures dans les yeux.
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.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
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’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) 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 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.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir
d’un respirateur d’adduction d’air homologué.
OM-255 254 Page 8
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux 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 lunettes de sécurité avec écrans latéraux même sous
votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
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.
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.
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
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 et AWS
A6.0 (voir les Normes de Sécurité).
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
Brancher le câble de masse 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, d’étincelles 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 porteélectrode 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.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
Porter des protections approuvés pour les
oreilles si le niveau sonore est trop élevé.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants médicaux.
Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
Les porteurs d’implants médicaux doivent consulter leur
médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz comprimé 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, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz comprimé, 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.
Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers existant en relation avec le moteur
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
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 des câbles
de batterie, des câbles de chargeur de batterie (le cas échéant) ou
de batterie d’entretien.
Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
Ne pas utiliser l’appareil de soudage pour charger des batteries ou
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf
si l’appareil dispose d’une fonctionnalité de charge de batterie
destinée à cet usage.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes, panneaux,
recouvrements et dispositifs de protection.
Arrêter le moteur avant d’installer ou brancher l’appareil.
Lorsque cela est nécessaire pour des travaux d entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
Les sources d’étincelles, flammes nues, cigarettes et autres
sources d’inflammation doivent être maintenues à l’écart des
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.
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 portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant de
mettre le moteur en marche.
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.
Respecter les consignes du fabricant de la batterie pour
travailler sur une batterie ou à proximité.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrêter le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
Toujours garder le pistolet en contact avec le réservoir lors du
remplissage.
Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.
Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher des parties chaudes à mains
nues.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
OM-255 254 Page 9
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du
moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.
Mettre des lunettes de sécurité et des gants, placer un torchon sur
le bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper
avant d’enlever le bouchon.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
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.
L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisible et inodore.
JAMAIS utiliser dans une maison ou garage,
même avec les portes et fenêtres ouvertes.
Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
2-4. Dangers liés à l’air comprimé
Un ÉQUIPEMENT PNEUMATIQUE risque
de provoquer des blessures ou même
la mort.
Une installation ou une utilisation incorrecte de
cet appareil pourrait conduire à des dégâts
matériels ou corporels. Seul un personnel
qualifié est autorisé à installer, utiliser et
entretenir cet appareil conformément à son
manuel d’utilisation, aux normes industrielles et
aux codes nationaux, d’état ou locaux.
Ne pas dépasser le débit nominal ou la capacité du compresseur
ou de tout équipement du circuit d’air comprimé. Concevoir
le circuit d’air comprimé de telle sorte que la défaillance
d’un composant ne risque pas de provoquer un accident
matériel ou corporel.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil
fonctionne. Seul un personnel qualifié est autorisé, et appliquant
les consignes du fabricant.
Ne pas modifier ou altérer le compresseur ou les équipements
fournis par le fabricant. Ne pas débrancher, désactiver ou
neutraliser les équipements de sécurité du circuit d’air
comprimé.
Utiliser uniquement des composants et accessoires
homologués par le fabricant.
Se tenir à l’écart de tout point présentant un danger de pincement
ou d’écrasement créé par l’équipement raccordé au circuit d’air
comprimé.
Ne pas intervenir sous ou autour d’un équipement qui n’est
soutenu que par la pression pneumatique. Soutenir l’équipement
de façon appropriée par un moyen mécanique.
MÉTAL CHAUD provenant du découpage ou du gougeage à l’arc risque de
provoquer un incendie ou une explosion.
Ne pas découper ou gouger à proximité de
produits inflammables.
Attention aux risques d’incendie: tenir un extincteur à proximité.
L’AIR COMPRIMÉ risque de provoquer
des blessures ou même la mort.
Avant d’intervenir sur le circuit d’air comprimé,
couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit d’air ne peut être mis
sous pression par inadvertance.
Détendre la pression avant de débrancher ou
de brancher des canalisations d’air.
Avant
d’utiliser
l’appareil,
contrôler
les composants du circuit d’air comprimé,
les branchements et les flexibles en
recherchant tout signe de détérioration, de fuite
et d’usure.
Ne pas diriger un jet d’air vers soi−même ou vers autrui.
Pour intervenir sur un circuit d’air comprimé, porter un équipement
de protection tel que des lunettes de sécurité, des gants de cuir,
une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
Pour rechercher des fuites, utiliser de l’eau savonneuse ou
un détecteur à ultrasons, jamais les mains nues. En cas
de détection de fuite, ne pas utiliser l’équipement.
Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
En cas d’injection d’air dans la peau ou le corps, demander
immédiatement une assistance médicale.
OM-255 254 Page 10
L’INHALATION D’AIR COMPRIMÉ risque
de provoquer des blessures ou même
la mort.
Ne pas inhaler d’air comprimé.
Utiliser l’air comprimé uniquement pour
découper ou gouger ainsi que pour l’outillage
pneumatique.
Une PRESSION D’AIR RÉSIDUELLE
ET DES FLEXIBLES QUI FOUETTENT
risquent de provoquer des blessures.
Détendre la pression pneumatique des outils et
circuits avant d’entretenir, ajouter ou changer
des accessoires et avant d’ouvrir le bouchon
de vidange ou de remplissage d’huile
du compresseur.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs
de protection.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
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.
Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant
de mettre le moteur en marche.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Ne pas toucher de pièces chaudes
du compresseur ou du circuit d’air.
Prévoir une période de refroidissement
avant d’intervenir sur l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils
recommandés et porter des gants de soudage et
des vêtements épais pour éviter les brûlures.
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT
peut provoquer des blessures.
Utiliser l’anneau de levage pour lever l’appareil
et les accessoires correctement installées
seuls, PAS les bouteilles de gaz. Ne pas dépasser le poids nominal maximal de l’œilleton
(voir les spécifications).
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.
Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94−110) lors du levage
manuelle de pièces ou équipements lourds.
LE SURCHAUFFEMENT peut
endommager le moteur électrique.
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.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
Porter un écran facial pour protéger le visage et
les yeux.
Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre 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.
Les PIÈCES MOBILES peuvent
causer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
OM-255 254 Page 11
LA SORTIE DE RECHARGE et L’EXPLOSION DE LA BATTERIE peuvent
provoquer des blessures.
La recharge de batterie n’existe pas sur tous les
modèles.
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 des
câbles de batterie, des câbles de chargeur de batterie (le cas
échéant) ou de batterie d’entretien.
Eviter de provoquer des étincelles avec les outils en travaillant
sur la batterie.
Ne pas utiliser l’appareil de soudage pour charger des batteries
ou faire démarrer des véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité de charge de
batterie destinée à cet usage.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (−) en premier lieu. Le rebrancher en
dernier lieu.
Les sources d’étincelles, flammes nues, cigarettes et autres
sources d’inflammation doivent être maintenues à l’écart des
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.
Respecter les consignes du fabricant de la batterie pour
travailler sur une batterie ou à proximité.
Les opérations de charge de batterie ne doivent être effectuées
que par des personnes qualifiées.
Pour enlever la batterie d’un véhicule pour la recharge,
débrancher tout d’abord le câble négatif (−) et le rebrancher en
dernier lieu. Pour éviter un arc, s’assurer que tous les
accessoires sont débranchés.
Ne charger que des batteries plomb−acide. Ne pas utiliser le
chargeur de batterie pour alimenter un autre circuit électrique
basse tension ou pour charger des batteries sèches.
Ne pas charger une batterie gelée.
Ne pas utiliser de câbles de charge endommagés.
Ne pas charger des batteries dans un espace fermé ou en
l’absence d’une ventilation.
Ne pas charger une batterie dont les bornes sont desserrées ou
présentant une détérioration comme par exemple un boîtier ou
un couvercle fissuré.
Avant de charger une batterie, sélectionner la tension de charge
correspondant à la tension de la batterie.
Régler les commandes de charge de batterie sur la position
d’arrêt avant de brancher la batterie. Veiller à ce que les pinces
de charge ne se touchent pas.
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
provoquer des blessures.
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.
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) 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 un blindage pour réduire les
interférences éventuelles.
Ranger les câbles de charge à distance du capot, des portes et
des pièces mobiles du véhicule.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
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.
OM-255 254 Page 12
L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-6. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipulation.
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-7. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700,
website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.)
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Portable Generators Safety Alert, U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814
(phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/portgen.pdf).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-8. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant
du circuit de soudage:
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
En ce qui concerne les implants médicaux :
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-255 254 Page 13
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05
OM-255 254 Page 14
Do not work on unit if engine is running. Stop engine first.
Safe21 2012−05
Do not smoke while fueling or if near fuel.
Safe22 2012−05
Stop engine before fueling.
Safe23 2012−05
Do not fuel a hot engine.
Safe24 2012−05
Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye
rating (see Specifications).
Safe25 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
=
Engine fuel plus flames or sparks can cause fire.
Safe45 2012−05
Remove unit from shipping crate. Remove Owner’s Manual from unit.
Follow instructions to install muffler.
Safe46 2012−05
Read Owner’s Manual. Read labels on unit.
Safe47 2012−05
Read Owner’s Manual. Follow instructions to activate battery.
Safe48 2012−05
OM-255 254 Page 15
0 - 50 h std
During the first 50 hours of operation keep welding load above 200
amperes. Do not weld below 200 amperes of output.
Safe54 2012−05
50 h std
After the first 50 hours of operation, change the engine oil and filter.
Safe55 2012−05
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-255 254 Page 16
3-2. Miscellaneous Symbols And Definitions
A
Stop Engine
Fast (Run, Weld/
Power)
Slow (Idle)
Start Engine
Starting Aid
(Preheat)
Battery (Engine)
Engine Oil
Pressure
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
FCAW Welding
Remote
Engine
Air Temperature Or
Engine
Temperature
Output
Alternating
Current
Stick (SMAW)
Welding
Constant Current
(CC)
GMAW Welding
TIG (GTAW)
Welding
Amperes
Time
3
V
h
Hours
Three Phase
Read Operator’s
Manual
Electrode
Connection
Work Connection
X
Duty Cycle
n1
Rated Idle
Speed
U0
n0
s
Seconds
1
Single Phase
Do Not Switch
While Welding
Circuit Protection
G
3
Engine-Driven,
Three-Phase
Alternator With
Rectifier
Rated No Load
Voltage (Average)
U2
Conventional
Load Voltage
Rated No Load
Speed
I
Current
Hz
n
I2
Hertz
Rated Load
Speed
Rated Welding
Current
OM-255 254 Page 17
SECTION 4 − SPECIFICATIONS
4-1. Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conce-emc 3 2011-09
ducted as well as radiated disturbances.
4-2. Weld, Power, And Engine Specifications
Welding
Mode
Weld Output
Range
Rated Welding
Output
Maximum
OpenCircuit
Voltage
Auxiliary Power
Rating
Engine
Generator
Single-Phase,
12 kVA/kW Peak,
10 kVA/kW, 84/42 A,
Continuous
120/240 V AC,
60 Hz
CAT Turbo C1.5T
Water−Cooled
Three−Cylinder 24 HP
Diesel Engine
Fuel
Capacity
Stick
325 A, 33 Volts DC
100% Duty Cycle
CC/DC
Stick/TIG
350A, 34 Volts DC
60% Duty Cycle
20 − 400 A
TIG
350 A, 24 Volts DC
100% Duty Cycle
85 VDC
400 A, 26 Volts DC
40% Duty Cycle
CV/DC
350 A, 31.5 Volts DC
100% Duty Cycle
14 − 40 V
85 VDC
4-3. Environmental Specifications
IP Rating
Operating Temperature Range
IP23
This equipment is designed for outdoor use. It may be stored, but is
not intended to be used outside during precipitation unless sheltered.
OM-255 254 Page 18
−40 to 104°F (−40 to +40°C)
11.5 gal
(43.5 L)
4-4. Dimensions, Weights, And Operating Angles
Dimensions
32 in. (813 mm)
35-3/4 in. (908 mm)
(to top of lift eye)
Height
G
26-1/4 in. (667 mm)
(mtg. brackets turned in)
Width
28-3/4 in. (730 mm)
(mtg. brackets turned out)
Depth
56 in. (1422 mm)
A
56 in. (1422 mm)
B
54 in. (1372 mm)
C
52 in in. (1321 mm)
D
2 in. (51 mm)
E
26 in. (660 mm)
F
7/8 in. (22 mm)
G
27-3/4 in. (705 mm)
H
9/16 in. (14 mm) Dia.
4 Holes
A
B
D
No fuel: 1018 lb (462 kg)
Do not exceed tilt angles or engine could
be damaged or unit could tip.
!
Do not move or operate unit where it could
tip.
C
30°
H
Front Panel End
Weight
!
20°
F
E
30°
20°
907 428−1
w/ fuel: 1100 lb (499 kg)
Lifting Eye Weight Rating:
2000 lb (907 kg) Maximum
4-5. CV Volt-Ampere Curves
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.
60
DC Volts
40
20
0
0
100
200
300
400
DC Amperes
247 985-A
OM-255 254 Page 19
4-6. CC Volt-Ampere Curves
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
DC Volts
80
For
best performance when
welding above 300 amperes,
place Engine Control switch in
Run position.
60
40
20
0
0
100
200
300
400
300
400
DC Amperes
B. TIG Mode
100
DC Volts
80
60
40
20
0
0
100
200
DC Amperes
247 987-A / 247 988-A
4-7. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
2.00
1.75
US Gal./Hr.
1.50
1.25
1.00
0.75
0.50
IDLE
0.25
0.00
0
50
100
150
200
250
300
350
400
DC Weld Amperes At 100% Duty Cycle
247 984-A
OM-255 254 Page 20
4-8. Duty Cycle And Overheating
1
1
100% Duty Cycle
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
This unit is rated for welding at
325 amperes continuously.
For
best performance when
welding above 300 amperes,
place Engine Control switch in
Run position.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Weld Amperes
400
300
200
0
10
20
30
40
50
60
70
80
90
100
% Duty Cycle
248 003−A
4-9. AC Generator Power Curve
The AC power curve shows the
generator power in amperes.
280
270
AC Volts
260
250
240
230
220
210
200
190
180
0
10
20
30
AC Amperes
40
50
60
247 989-A
OM-255 254 Page 21
SECTION 5 − INSTALLATION
5-1. Serial Number And Rating Label Locations
The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
5-2. Installing Welding Generator
Movement
!
Do not move or operate unit
where it could tip.
!
Always securely fasten welding generator onto transport
vehicle or trailer and comply
with all DOT and other applicable codes.
NOTICE − Do not install unit where
air flow is restricted or engine may
overheat.
OR
OR
See Section 4-4 for lifting eye rating.
See Section 5-3 for mounting
information.
Location/Airflow Clearance
OR
18 in.
(460 mm)
18 in.
(460 mm)
18 in.
(460 mm)
OR
18 in.
(460 mm)
18 in.
(460 mm)
install3 2008-01 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712
OM-255 254 Page 22
5-3. Mounting Welding Generator
!
Supporting The Unit
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.
NOTICE − Do not mount unit by
supporting the base only at the four
mounting brackets. Use crosssupports to adequately support unit
and prevent damage to base.
2
Mounting Surface:
1
2
OR
Cross-Supports
Mounting Brackets (Supplied)
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brackets.
3
1
4
1/2 in. Bolt And Washer
(Minimum − Not Supplied)
3/8-16 x 1 in. Screws
(Supplied)
To Bolt Unit In Place:
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
1
Mount unit to truck or trailer with 1/2
in. (12 mm) or larger hardware (not
supplied).
Using Mounting Brackets
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
2
Welding Unit In Place
Bolting Unit In Place
3
2
4
Tools Needed:
9/16 in.
install3 2008--01 803 274 / 200 864-A / 803 231
OM-255 254 Page 23
5-4. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
rot_grnd2 2012−03 − 800 652-D
!
Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
!
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Generators.
!
Bed liners, shipping skids, and
some running gear insulate the
welding generator from the vehicle
!
frame. Always connect a ground
wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.
1
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
lift support equipment.
Connect cable from equipment ground
terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.
2
3
Equipment Grounding Terminal (On
Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Electrically bond generator frame to vehicle frame by metal-to-metal contact.
5-5. Installing Exhaust Pipe
!
Stop engine and let cool.
Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in.
Exhaust Pipe3 2010−04 / Ref 803 582
OM-255 254 Page 24
5-6. Connecting The Battery
!
Connect negative (−) battery
cable last.
Close
door after connecting
battery.
−
+
Shown with rocker panel removed.
CAT engine models may require removal of
oil filter in order to remove battery.
Tools Needed:
1/2 in.
REF: Conn_Batt2 2010−04 / S-0756-C / 161-002
Notes
OM-255 254 Page 25
5-7. Engine Prestart Checks
Follow run-in procedure in engine manual. If unburned fuel
and oil collect in exhaust pipe during run-in, see Section 10.
Check radiator coolant
level when fluid is low in
recovery tank.
Full
Full
Diesel
Capacity:
10 qt (9.5 L)
Coolant Recovery Tank
Hot Full
Cold Full
Full
907 478−1a
Check all engine fluids daily.
Engine stops if fuel level is low.
Engine must be cold and on a level surface.
Oil
Automatic shutdown system stops engine if
oil pressure is too low, coolant temperature
is too high, or fuel level is low.
After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
This unit has a low oil pressure shut-
Coolant
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 10.
Fuel
NOTICE − Do not use gasoline. Gasoline
will damage engine.
Add fresh diesel fuel before starting (see
engine maintenance label for fuel specifications). Leave filler neck empty to allow room
for expansion.
OM-255 254 Page 26
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.
Unit is shipped with an engine coolant mixture of water and ethylene glycol base antifreeze rated to −34° F (−37° C). Add anti-
freeze to mixture if using the unit in temperatures below −34° F (−37° C).
Keep radiator and air intake clean and free
of dirt.
NOTICE − Incorrect engine temperature
can damage engine. Do not run engine without a properly working thermostat and radiator cap.
To improve cold weather starting:
Use Preheat switch (see Section 6-2).
Keep battery in good condition. Store
battery in warm area.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel information.
Use correct grade oil for cold weather
(see Section 8-1).
5-8. Weld Output Terminals
1
2
256 735-A
1
Negative (−) Weld Output Terminal
2
Positive (+) Weld Output Terminal
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
TIG (GTAW) Welding
For TIG welding Direct Current Electrode
Negative (DCEN), connect torch to Negative (−) terminal and work cable to Positive
(+) terminal.
MIG And FCAW Welding
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect wire
Use Process switch to select type of weld
output (see Section 6-2).
Stick Welding
For Stick welding Direct Current Electrode
Positive (DCEP), connect electrode holder
cable to Positive (+) terminal and work
cable to Negative (−) terminal.
feeder cable to Positive (+) terminal and
work cable to Negative (−) terminal.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
CAC-A Gouging
For CAC-A connect electrode holder cable
to Positive (+) terminal and work cable to
Negative (−) terminal.
5-9. Connecting To Weld Output Terminals
!
Stop engine.
!
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your machine.
Tools Needed:
3/4 in.
1
3
4
5
6
2
Do not place anything between weld
cable terminal and copper bar. Make
sure that the surfaces of the weld
cable terminal and copper bar are
clean.
1
Correct Weld Cable Connection
2
Incorrect Weld Cable Connection
3
4
5
6
Weld Output Terminal
Supplied Weld Output Terminal Nut
Weld Cable Terminal
Copper Bar
Remove supplied nut from weld output
terminal. Slide weld cable terminal onto
weld output terminal and secure with nut
so that weld cable terminal is tight against
copper bar.
803 778-B
OM-255 254 Page 27
5-10.
Selecting Weld Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
!
* This
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
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)
Stop engine before
connecting to weld
output terminals.
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)
Do not use worn,
damaged,
undersized, or poorly
spliced cables.
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x3/0
(2x95)
2x4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0
(2x70)
2x3/0
(2x95)
2x4/0
(2x120)
2x4/0
(2x120)
Weld Output
Terminals
!
150 ft
(45 m)
10 − 100% Duty Cycle
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-J 2011−07
5-11. Connecting To Remote 14 Receptacle RC14
Socket*
Socket Information
Not all models have contactor control. See description of front panel controls and
circuit diagram.
A
24 volts AC. Protected by supplementary protector.
B
Contact closure to A completes 24 volt AC contactor
control circuit.
C
Output to remote control:+10 volts DC in MIG mode;
0 to +10 volts DC in Stick or 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 maximum.
F
Current feedback: 1 volt per 100 amperes.
H
Voltage feedback: 1 volt per 10 arc volts.
GND
K
Chassis common.
NEUTRAL
G
Circuit common for 24 AC circuit.
24 VOLTS AC
*The remaining sockets
are not used.
REMOTE
OUTPUT
CONTROL
Accessories depend
on unit capabilities.
OR
Rmt14_1 2010−04
OM-255 254 Page 28
Notes
OM-255 254 Page 29
SECTION 6 − OPERATING WELDING GENERATOR
6-1. Front Panel Controls (See Section 6-2)
6
8
7
9
10
5
11
1
2
3
4
North American Auxiliary Power Panel Shown.
256 735-A / 907 428−1
OM-255 254 Page 30
6-2. Description Of Front Panel Controls (See Section 6-1)
Engine Starting Controls
1
Preheat Switch
Use switch to energize starting aid for cold
weather starting (see starting instructions following).
2
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.
For
best performance when welding
above 300 amperes, place Engine Control switch in Run position.
To Start:
NOTICE − Do not use ether.
If engine does not start, let engine come
to a complete stop before attempting restart.
Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
Below 325 F (05 C): turn engine control switch
to Run position. Push Preheat switch up for 6
seconds. Turn Engine Control switch to Start.
Release Engine Control switch and Preheat
switch when engine starts.
Do not operate Preheat switch for more
than 20 seconds at a time.
To Stop: turn Engine Control switch to Off
position.
Engine Gauges, Meters, And Lights
See Section 6-7 for complete fuel/hour
gauge information.
3
Fuel/Hour Gauge
Use gauge to check fuel level, total engine operating hours, or hours to oil change.
To check fuel level or engine hours when engine is not running, turn Engine Control switch
to Run/Idle position.
4
Engine Indicator Light
Light goes on and engine stops if fuel is low,
engine temperature exceeds 230° F (110° C)
or engine oil pressure is below 10 psi (69
kPa).
Normal engine temperature is 180 - 203
F (82 - 95 C). Normal oil pressure is 30
- 60 psi (207 - 414 kPa).
NOTICE − Do not run engine until trouble is
fixed.
5
Engine Coolant Temperature Gauge
Normal temperature is 180 - 203° F (82 - 95°
C). Engine stops if temperature exceeds 230°
F (110° C).
Weld Controls
6
Remote Control Receptacle
Use receptacle to connect remote controls,
wire feeders, and tools requiring 24 VAC.
When a remote control is connected to the
Remote receptacle, the Auto Sense Remote
feature automatically switches voltage/amperage control to the remote control (see Section 6-6).
With remote control connected, weld output is
determined by a combination of front panel
and remote control voltage/amperage settings.
If no remote control is connected to the Remote receptacle, the front panel Voltage/Amperage control adjusts voltage and amperage.
If a remote device connected to Remote
Receptacle RC14 is faulty or is disconnected during operation, the meters display Help 25 (see Section 8-10). Clear
fault by stopping and restarting the unit or
by turning Process/Contactor switch to
another position.
7
Process/Contactor Switch
See Section 6-3 for Process/Contactor
switch information.
8
Arc Control
See Section 6-4 for Arc Control information.
9
Voltage/Amperage Control
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage.
With Process/Contactor switch in any Wire
(MIG) position, use control to adjust voltage.
Control limits the remote amperage in Stick or
TIG mode, but has no effect in Wire (MIG)
modes.
Weld Meters
Weld meters also work in combination to
display troubleshooting help codes (see
Section 8-10).
10 DC Voltmeter
Voltmeter displays preset voltage (MIG welding) with contactor off, and actual output voltage with the contactor on. Voltmeter displays
voltage at the weld output terminals, but not
necessarily the welding arc due to resistance
of cable and connections.
To set voltage, turn Process/Contactor switch
to MIG or FCAW position. Turn V/A control
until desired voltage is displayed on Voltmeter. When welding is finished, voltmeter displays weld voltage and then defaults to preset
voltage.
11 DC Ammeter
Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
output amperage when welding.
To set amperage, turn Process/Contactor
switch to Stick or TIG position. Turn V/A control until desired amperage is displayed on
Ammeter. When welding is finished, ammeter
displays weld amperage and then defaults to
preset amperage.
OM-255 254 Page 31
6-3. Process/Contactor Switch
1
1
Process/Contactor Switch
!
Weld output terminals are energized when Process/Contactor
switch is in an Electrode Hot
position and the engine is running.
Use switch to select weld process and
weld output on/off control (see table below).
Place switch in Remote On/Off Switch
Required 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 mode for air carbon arc
(CAC-A) cutting and gouging.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 6-5).
Ref. 246 345-B / Ref. 907 428−1
REMOTE ON/OFF REQUIRED
ELECTRODE HOT
Switch Setting
Typical Process Applications (DC Only)
Electrode Hot – MIG VS
MIG solid wire uses a voltage sensing (VS) feeder that does not require a control cable
back to the welding generator.
Electrode Hot – FCAW VS
FCAW (Flux Cored Arc Welding) uses a voltage sensing (VS) feeder that does not require a control cable back to the welding generator.
Electrode Hot - Stick
Stick welding with or without a remote amperage control. Strike an arc to start welding.
Electrode Hot – TIG Lift Arc
Lift Arc TIG: touch tungsten to work and lift to start welding. Uses circuitry internal to the
welding generator to aid arc start. Can be used with or without a remote control.
Remote ON/OFF Required - TIG
High Frequency TIG or Scratch Start TIG welding. High frequency TIG starting with remote foot control allows remote On/Off and Amperage control. Another typical application
is a simple TIG rig with a remote control device.
Remote On/Off Required - Stick
Stick welding with RFC-14 control allows remote On/Off and Amperage control. This can
help eliminate accidental arc strikes.
Remote On/Off Required - FCAW
FCAW using a constant speed feeder. Use feeders with remote voltage control, or use a
Spoolmatic 30A with WC 24 control.
Remote On/Off Required - MIG
MIG solid wire using a constant speed feeder. Use feeders with remote voltage control, or
use a Spoolmatic 30A with WC 24 control.
OM-255 254 Page 32
6-4. Arc Control
1
Arc Control
Stick
Control adjusts Dig when Stick is selected on mode switch.
1
When control is set toward minimum,
short-circuit amperage at low arc
voltage is the same as normal welding amperage.
When set toward maximum, shortcircuit amperage is increased at low
arc voltage to help prevent the electrode from sticking while welding (see
volt-ampere curves in Section 4-6).
Select setting best suited for application.
FCAW/MIG
Control adjusts inductance when
FCAW or MIG position is selected on
the mode switch. Inductance determines the “wetness” of the weld
puddle. Increasing Arc Control setting decreases inductance, thereby
increasing puddle fluidity (“wetness”). Decreasing Arc Control setting increases inductance, decreasing puddle fluidity.
TIG
When the control is set below 1, Auto
Stop is a variable function of pre-set
weld amperage. This is used with a
short arc length where flare at arc
shutdown cannot be tolerated.
When the control is set above 1, Auto
Stop voltage threshold is a set value
based on pre-set weld amperage (I)
as follows:
I <= 50 A, V=17
I >50 to <=100 A, V=22
I >100 to <=190 A, V=25
I >190A, V=30
This allows for a longer arc length
(such as when “walking the cup”),
where nuisance shutdowns are undesirable.
Control is not functional when TIG
Remote mode is selected.
257 145-A
OM-255 254 Page 33
6-5. Lift-Arct TIG With Auto-Stopt
Arc Start With Lift-Arc TIG
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted.
Arc Start With Lift-Arc
1
Select Lift-Arc TIG at Process/
Contactor switch.
2
Turn gas on.
1
2
Touch or scratch.
Lift at any angle.
Touch tungsten electrode to
workpiece at weld start point.
Slowly lift electrode. Arc is started
when electrode is lifted.
Maintain shielding gas coverage
and eliminate tungsten and workpiece contamination by using
Auto-Stop to end the arc.
Arc End With Auto-Stop
1
2
3
Arc End With Auto-Stop:
1
2
3
While welding.
Lift torch to start Auto-Stop.
Arc stops.
Move torch back down to
maintain gas coverage and
prevent contamination.
WM Marketing
Notes
OM-255 254 Page 34
6-6. Remote Voltage/Amperage Control
1
Remote 14 Receptacle RC14
Connect optional remote control to RC14 (see
Section 5-11).
When a remote control is connected to the
1
2
Remote receptacle, the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control. When a device is connected to the Remote receptacle, remote voltage/amperage control is always available regardless
of the position of the Process/Contactor
switch.
3
2
3
In Example:
Min = 20 A DC
Max = 205 A DC
Voltmeter Shows Open-Circuit
Voltage When Not Welding, Arc
Voltage While Welding
56
Connect Remote
Control To Remote
Receptacle RC14
Set TIG or STICK Process
Voltmeter Shows Preset
Output When Not Welding,
Actual Voltage While Welding
28
0
Voltmeter
Ammeter
205
Turn Remote Control On. Adjust Optional Remote
Control to 100%
Ammeter Shows Preset
Output When Not Welding,
Actual Amperage While
Welding
Set V/A Control
To Desired Maximum
Weld Output Using Weld
Meters
Ammeter Shows Zero
Max (205 A DC)
Min (20 A DC)
Adjust Optional Remote
Control to desired
weld output
Weld meters show preset
output when not welding.
Adjust Optional Remote
Control to desired
weld output
Connect Remote
Control To Remote
Receptacle RC14
Set WIRE Process
0774 / Ref.246 345-B / Ref. 907 428−1
OM-255 254 Page 35
6-7. Fuel/Hour Gauge Descriptions
OM-255 254 Page 36
6-8. Operating Optional Engine Block Heater
1
Engine Block Heater Plug
Use heater to maintain a constant
engine coolant temperature.
To turn on heater, connect heater
plug to 120 volts AC receptacle.
Coolant Heater
Specifications
Watts
Volts ±10%
400
120
!
Do not run engine while engine block heater is on.
NOTICE −In extremely cold weather, heater should be connected to
power source when engine is
warm.
!
The area near the engine
block heater gets hot.
Disconnect plug to turn off heater.
1
Coolant Heater1 2012−05 803 562 / Ref. 803 145
Notes
OM-255 254 Page 37
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. North American Auxiliary Power Receptacles
1
2
3
4
5
256 735-A
!
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacle to power
life support equipment.
!
Test GFCI monthly. See Section 7-3
for GFCI information and for resetting and testing procedures.
overload. If CB5 opens, the receptacles do
not work. Place CB5 switch in On position
to reset circuit breaker.
RC11 supplies 60 Hz single-phase power
at weld/power speed. Maximum output
from RC11 is 10 kVA/kW.
If a supplementary protector continues
Unplug power cord before attempting to service accessories or tools.
3
Supplementary Protector CB6
120 V 20 A AC GFCI Receptacles
GFCI1 And GFCI2
Supplementary Protector CB4
Generator power decreases as weld
1
4
5
Supplementary Protector CB5
2
120/240 V 50 A AC Receptacle RC11
!
GFCI1 and GFCI2 supply 60 Hz single-phase power at weld/power speed.
CB4 protects GFCI2 and CB6 protects
GFCI1 from overload. If a supplementary
protector opens, the receptacle does not
work. Press button to reset.
Maximum output from each receptacle is
2.4 kVA/kW.
Supplementary protector CB5 protects receptacles and the generator winding from
OM-255 254 Page 38
to open, contact Factory Authorized
Service Agent.
output increases.
Combined output of all receptacles is limited to the 10 kVA/kw rating of the generator.
EXAMPLE: If 15 A is drawn from each 120
V receptacle , only 26 A is available at the
240 V receptacle:
2 x (120 V x 15 A) + (240 V x 26 A) =
10.0 kVA/kW
7-2. Export Auxiliary Power Receptacles
1
3
2
4
5
256 593-A
!
Use GFCI protection when operating
auxiliary equipment. If unit does not
have GFCI receptacles, use GFCIprotected extension cord. Do not
use GFCI receptacle to power life
support equipment.
!
Unplug power cord before attempting to service accessories or tools.
1
2
switch in On position to reset circuit breaker.
3
Supplementary Protector CB4
CB4 protects GFCI1 from overload. If supplementary protector opens, the receptacle
does not work. Press button to reset.
4
110V 20 A AC Receptacle GFCI1
220V 16 A AC Receptacle RC11
5
110V16A AC Receptacle RC12
Earth Leakage Circuit Breaker ELCB1
Receptacles supply 50/60 Hz single-phase
power.
ELCB1 protects receptacle from overload
and earth leakage fault. If circuit breaker
opens, the receptacle does not work. Place
Maximum combined output of all receptacles is 4 kVa/kW.
!
Test GFCI monthly. See Section 7-3
for GFCI information and for resetting and testing procedures.
At least once a month, run engine at
weld/power speed and press test button to verify ELCB1is working properly.
If a supplementary protector or circuit
breaker continues to open, contact
Factory Authorized Service Agent.
Generator power decreases as weld
output increases.
OM-255 254 Page 39
7-3. GFCI Receptacle Information, Resetting And Testing
1
2
3
4
!
Test and reset GFCI
only at Run speed.
RotGFCI1 2012−05
!
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacle to power
life support equipment.
!
Unplug power cord before attempting to service accessories or tools.
1
120 V 20 A AC GFCI Receptacle
2
GFCI Receptacle Test Button
3
GFCI Receptacle Reset Button
4
GFCI Indicator Light (LED)
If a ground fault is detected, the GFCI Reset
button pops out, and the circuit opens to
disconnect power to the faulty equipment.
A GFCI receptacle does not protect against
circuit overloads, short circuits, or shocks
not related to ground faults. Reset and test
GFCI receptacle according to the following
procedures.
Resetting/Testing GFCI Receptacle
!
!
GFCI Receptacles
GFCI receptacles protect the user from
electric shock if a ground fault occurs in
equipment connected to the receptacle. A
ground fault occurs when electrical current
takes the shortest path to ground (which
could be through a person) rather than follow its intended safe path.
OM-255 254 Page 40
!
Test GFCI monthly. See Testing
GFCI Receptacle.
Do not test or reset GFCI receptacles at idle speed/low voltage or
the GFCI will be damaged and not
provide protection from electric
shock caused by a ground fault.
If LED blinks, stop using GFCI receptacle and have it replaced by a
Factory Authorized Service Agent.
Resetting GFCI Receptacles
If a GFCI fault occurs, stop engine and disconnect equipment from GFCI receptacle.
Check for damaged or wet tools, cords,
plugs, etc. connected to the receptacle.
Start engine and operate at Run (weld/
power) speed. Press GFCI Reset button.
Reconnect equipment to GFCI receptacle.
If GFCI Reset button pops out again, check
the equipment and repair or replace if faulty.
Testing GFCI Receptacles
GFCI testing must be done with engine
running at Run (weld/power) speed.
Start engine and operate at Run (weld/
power) speed.
Press the GFCI Test button. The GFCI Reset button should pop out.
Press the GFCI Reset button.
Have GFCI replaced by a Factory Authorized Service Agent if any of the following occur:
GFCI does not trip when tested
LED blinks
GFCI does not reset.
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Maintenance Label
OM-255 254 Page 41
8-2. Routine Maintenance
!
Recycle engine
fluids.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Stop engine before maintaining.
See
Engine Manual and Maintenance Label
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
= Replace
Reference
Every
8
Hours
Section 5-7,
8-7
Coolant Level
Fuel Level
Oil Level
Oil, Fuel Spills
Every
50
Hours
Weld Terminals
Every
100
Hours
Section 8-4
Battery Terminals
Every
250
Hours
Air Cleaner Hoses
1/2 in.
(13 mm)
Weld Cables
Fan Belt Tension
Air Cleaner Element
Unreadable Labels
NOTICE − Change engine
oil and filter after initial 50 to
75 hours of use.
Oil Oil Filter
Engine
Manual,
Section 8-5,
8-7
Spark Arrestor
Every
500
Hours
Engine
Manual,
Section 8-7
Inline Fuel Filter
Every
1000
Hours
Fuel Filter
Radiator Thermostat
FUEL
OR
SLUDGE
Radiator Fluid Level
Inside Unit
Valve Clearance*
Drain Sludge
Slip Rings*
Brushes*
Every
2000
Hours
Injectors*
= Clean unit exterior, including stainless steel, frequently to prevent rust and corrosion.
OM-255 254 Page 42
Section 5-7,
8-3, 8-6,
8-7, and
Engine
Manual
Caterpillar Corporate Headquarters
100 North East Adams Street
Peoria, Illinois USA 61629
(309) 675−1000
http://www.cat.com/engines
Cat Dealer Locator:
Use website to find local engine service facility.
Service
2
When a problem arises concerning the operation or service of the engine, the problem will normally be managed by the dealer
in your area.
If your problem cannot be resolved at
the dealer level without additional
assistance, call a Field Service
Coordinator at 1-800-447-4986.
Please follow the above steps in sequence
if a problem arises.
3
If your needs still have not been met,
submit the matter in writing to:
www.caterpillar.com
Your satisfaction is a primary concern to
Caterpillar and to Caterpillar dealers. If you
have a problem that has not been handled
to your complete satisfaction, follow these
steps:
1
Caterpillar Inc.
Manager, Customer Service,
Engine Division
Mossville Bldg A
P.O. Box 600
Peoria, IL 61552-0600
Discuss your problem with a manager
from the dealership.
Website Address
Altitude
Contact the Caterpillar applications department for information on the effect of ambient
conditions on Caterpillar engines.
8-3. Checking Generator Brushes
!
Stop engine and let cool.
1
Generator Brush Assembly
Mark and disconnect leads at brush holder assembly. Remove assembly. Press
on brush to be sure springs compress.
Replace assembly if brushes are damaged or if brush material is at or near minimum length. Check length from brushholder surface.
1
New Length:
5/8 in. (16mm)
Minimum Length:
1/4 in. (6.5mm)
Replace Assembly if
Brushes are Damaged
GenBrush2 2012-05 / Ref 205 725
OM-255 254 Page 43
8-4. Servicing Air Cleaner
Blow
1
2
3
Keep nozzle
2 in. (51 mm)
from element.
4
Inspect
Optional
5
aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 226 386-B
!
ment, 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.
Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine damage caused by using a damaged element
is not covered by the warranty.
The air cleaner primary element can
be cleaned but the dirt holding capacity
of the filter is reduced with each cleaning. The chance of dirt reaching the
clean side of the filter while cleaning
and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment damage when determining whether to
clean or replace the primary element.
If you decide to clean the primary ele-
OM-255 254 Page 44
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.
1
Housing
2
Safety Element (Optional)
3
Primary Element
4
Dust Cap
5
Dust Ejector
To clean air filter:
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
NOTICE − 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).
8-5. Inspecting And Cleaning 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
!
1
Stop engine and let cool.
Reinstall cleanout plug.
2
Tools Needed:
3/8 in.
907 427-2
8-6. Servicing Engine Cooling System
!
Stop engine and let cool.
1
Radiator Cap Cover
2
Radiator Draincock
3
Coolant Recovery Tank
Change coolant according to engine
manual. Add coolant according to engine
maintenance label.
1
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.
2
3
Coolant1 2010−04 / Ref. 907 427-6
OM-255 254 Page 45
8-7. Servicing Fuel And Lubrication Systems
Tools Needed:
!
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
2
3
Oil Filter
Oil Drain Valve And Hose
Oil Fill Cap
4
Secondary (Canister) Fuel Filter Location
5
Primary (In-Line) Fuel
Filter
6
Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve
through hole in base. See engine
manual and engine maintenance
label for oil/filter change information.
To replace secondary (canister)
fuel filter:
Turn filter retaining ring counterclockwise to remove. Pull filter
straight down to remove.
2
6
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new filter. Install new filter and reinstall retaining ring.
Inspect fuel lines, and replace if
cracked or worn.
To drain water from fuel system:
See engine manual.
3
To replace primary (in-line) fuel
filter:
Note direction of fuel flow as indicated by arrow on side of filter. Remove fuel line clamps and disconnect fuel lines from fuel filter. Replace filter, reconnect fuel lines, and
reinstall clamps.
5
To drain sludge from fuel tank:
1
!
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.
!
Properly lift unit and secure
in a level position. Use adequate blocks or stands to
support unit while draining
fuel tank.
4
Attach 1/2 ID hose to drain valve.
Put metal container under drain,
and use screwdriver to open
sludge drain valve. Close valve
when sludge has drained. Remove
hose.
Close door.
Ref. 804 009−C / 907 478−1a
OM-255 254 Page 46
8-8. Overload Protection
!
Stop engine.
When a circuit breaker, supplementary protector, or fuse
opens, it usually indicates a
more serious problem exists.
Contact Factory Authorized
Service Agent.
1
Fuse F1
F1 protects the stator exciter winding from overload. If F1 opens, weld
and generator power is low or stops
entirely.
2
1
3
Circuit Breaker CB1 (Not
Shown)
Supplementary Protector CB2
4
Supplementary Protector CB3
5
Supplementary Protector CB8
CB1 protects the engine battery circuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
when the fault is corrected.
CB2 protects the engine wiring harness. If CB2 opens, the engine will
not crank.
CB3 protects part of the weld control
wiring harness. If CB3 opens, weld
and generator power output stops.
CB8 protects the 24 volt ac output to
remote receptacle RC14. If CB8
opens, 24 volt output to RC14 stops.
3
Press button to reset supplementary
protector.
4
5
803 562 / 803 566
OM-255 254 Page 47
8-9. Adjusting Engine Speed
The engine is electronically governed. Engine speed adjustment must be done by an engine Factory Authorized Service Agent. Tampering with
adjustments may affect engine warranty.
8-10. Voltmeter/Ammeter Help Displays
1
HL.P
20
HL.P
21
HL.P
22
HL.P
25
2
3
4
Use the Voltmeter/Ammeter help displays
to diagnose and correct fault conditions.
vice Agent check PC1, PC2, and the wiring
between PC1 and PC2.
When a help code is displayed normal-
2
ly weld output has stopped but generator power output may be okay.
To reset help displays, stop
unit and
then restart. See item 4 below to reset
Help 25 display.
1
Help 20 Display
Indicates a failure of meter display module
PC2, or the wiring between PC2 and main
control module PC1, or PC1. If this display
is shown, have Factory Authorized Ser-
Help 21 Display
Thermistor TH1 in the IGBT module on the
heat sink has failed. If this display is
shown, have Factory Authorized Service
Agent check TH1, and the wiring between
TH1 and PC1.
3
Help 22 Display
Indicates the IBGT module heat sink has
overheated. If this display is shown, check
generator cooling system and/or reduce
duty cycle. Keep engine access door
closed when running to maintain proper
cooling air flow past the heat sink. Allow
unit to cool before restarting. If problem
continues, have Factory Authorized Service Agent check unit.
4
Help 25 Display
Indicates a remote device connected to
Remote Receptacle RC14 may be faulty.
Help 25 is also displayed whenever a remote device has been connected to RC14
and then disconnected. Clear fault by stopping and restarting the unit or by turning
Process/Contactor switch to another position. If problem continues, have Factory
Authorized Service Agent check the remote device, filter board PC6, and main
control module PC1.
8-11. Maintaining Stainless Steel (Models With Optional Package)
Stainless steel is very resistant to rust and corrosion; however, it must be kept clean to ensure rust and corrosion resistance. Units used
in corrosive environments (chlorine or salt water environment for example) should be cleaned with mild soap and water frequently. If dirt
build−up occurs, use a stainless steel cleaner to remove build−up. With proper maintenance, stainless steel maintains its luster and appearance.
OM-255 254 Page 48
8-12.
Troubleshooting
Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10).
A. Welding
Trouble
Remedy
No weld output; generator power output Have Factory Authorized Service Agent check main rectifier and main control module PC1.
okay at AC receptacles.
Reset supplementary protector CB8 (see Section 8-8). Check for faulty remote device connected to
RC14.
Check and secure connections to Remote Control receptacle RC14 (see Section 5-11).
Check Voltmeter/Ammeter help displays (see Section 8-10).
No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at AC receptacles.
Reset supplementary protector CB3. (see Section 8-8).
Check fuse F1, and replace if open (see Section 8-8). If F1 is open, have Factory Authorized Service
Agent check the field excitation circuit.
Check Voltmeter/Ammeter help displays (see Section 8-10).
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.
Have Factory Authorized Service Agent check brushes and slip rings.
High weld output.
Have Factory Authorized Service Agent check main control module PC1 and hall device HD1.
Low weld output.
Check fuse F1, and replace if open (see Section 8-8). If F1 is open, have Factory Authorized Service
Agent check the rotor.
Low open-circuit voltage.
Have Factory Authorized Service Agent check main control module PC1, field excitation circuit, and main
rectifier.
No remote fine amperage control.
Repair or replace remote control device.
Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 5-11).
No 24 volt AC output at Remote recep- Reset supplementary protector CB8 (24 volt) (see Section 8-8).
tacle RC14.
OM-255 254 Page 49
B. Standard Generator Power
Trouble
Remedy
No generator power output at AC recep- Reset receptacle supplementary protectors (see Section 7-1).Check and reset GFCI receptacles if netacles; weld output okay.
cessary (see Section 7-3).
No generator power or weld output.
Disconnect equipment from generator power receptacles during start-up.
Check fuse F1, and replace if open (see Section 8-8). Have Factory Authorized Service Agent check field
excitation circuit.
Reset supplementary protector CB3 (see Section 8-8).
Check Voltmeter/Ammeter help displays (see Section 8-10).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power AC re- Have Factory Authorized Service Agent check field excitation circuit.
ceptacles.
Low output at generator power AC re- Check fuse F1, and replace if open (see Section 8-8). If F1 is open, have Factory Authorized Service
ceptacles.
Agent check the rotor.
C. Engine
Trouble
Engine will not crank.
Remedy
Check battery, and replace if necessary. It may be necessary to remove oil filter to replace battery.
Check battery connections and tighten if necessary.
Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-8).
Have Factory Authorized Service Agent check engine wiring harness and components.
Reset supplementary protector CB2 (see Section 8-8).
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check Engine Control switch S1, Fuel/Hour gauge FUEL/HM,
and control relay CR2.
Engine cranks but does not start.
Check fuel level.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check control relay CR1, Fuel/Hour gauge FUEL/HM, fuel
solenoid FS1, and the fuel pump.
Air in fuel system. See engine manual.
Engine hard to start in cold weather.
Use Preheat switch S4 (see Section 6-2).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 8-1).
Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow
plug.
Engine suddenly stops.
Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 5-7 ).
Check fuel/hour meter for indication of shutdown.
Reset supplementary protector CB2 and/or clear fault causing circuit breaker CB1 to trip (see Section
8-8). Have Factory Authorized Service Agent check engine alternator, engine harness, fuel solenoid
FS1, and the fuel pump.
Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, integrated rectifier SR2, fuel solenoid FS1, and the fuel pump.
See engine manual.
OM-255 254 Page 50
Trouble
Engine slowly stopped and cannot be
restarted.
Remedy
Check fuel level.
Check fuel/hour meter for indication of shutdown.
Check engine air and fuel filters (see Sections 8-4 and 8-7).
See engine manual.
Battery discharges between uses.
Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary. It may be necessary to remove oil filter to replace battery.
Periodically recharge battery (approximately every 3 months).
Engine idles, but does not come up to
weld speed.
Have engine Factory Authorized Service Agent check engine speed control system.
Engine does not run at idle speed.
Have engine Factory Authorized Service Agent check engine speed control system.
Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 10).
wetstacking occurs.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-255 254 Page 51
SECTION 9 − ELECTRICAL DIAGRAMS
Figure 9-1. Circuit Diagram For North American Welding Generator
OM-255 254 Page 52
255 250-B
OM-255 254 Page 53
Figure 9-2. Circuit Diagram For Export Welding Generator
OM-255 254 Page 54
257 006-A
OM-255 254 Page 55
SECTION 10 − RUN-IN PROCEDURE
run_in1 2007−04
10-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts
weld output and do not exceed duty
cycle or equipment damage may
occur.
1
2
1
Welding Generator
Run diesel engines near rated voltage and current during run-in period
to properly seat piston rings and
prevent wetstacking. See nameplate, rating label, or specifications
section in this manual to find rated
voltage and current.
NOTICE − Do not idle engine longer
than necessary. Piston rings seat
faster if engine runs at weld/power
rpm, and the welding generator is
kept loaded during run-in.
2
Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional engine run-in information.
OM-255 254 Page 56
10-2. Run-In Procedure Using Load Bank
4
2
1
!
Stop engine.
!
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
!
Keep exhaust and pipe away
from flammables.
NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty
cycle or equipment damage may
occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or generator auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe
correct
polarity.
3
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator A/V control so
load equals rated voltage and
current of generator (see nameplate, rating label, or the specifications section in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
NOTICE − Check oil level frequently during run-in; add oil if needed.
It is recommended to run the welding generator for two hours minimum and up to four hours under
load. Place A/V control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.
!
Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0683
OM-255 254 Page 57
10-3. Run-In Procedure Using Resistance Grid
6
2
!
Stop engine.
!
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
!
Keep exhaust and pipe away
from flammables.
NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty
cycle or equipment damage may
occur.
1
1 Resistance Grid
Use grid sized for generator rated
output.
Turn Off grid.
2 Welding Generator
Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connectors (polarity is not important).
4
3
5
Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several
minutes.
Set grid switches and then adjust generator A/V control so
load equals rated voltage and
current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).
4
+
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
NOTICE − Check oil level frequently during run-in; add oil if needed.
It is recommended to run the welding generator for two hours minimum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.
!
Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
OM-255 254 Page 58
SECTION 11 − GENERATOR POWER GUIDELINES
The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
11-1. Selecting Equipment
1
2
1
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
Be sure equipment has double
insulated symbol and/or wording on it.
!
2
Do not use 2-prong plug unless equipment is double insulated.
3
OR
gen_pwr 2012−03 − ST-800 577
11-2. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
800 652-D
!
!
1
2
Always ground generator frame to
vehicle frame to prevent electric
shock and static electricity hazards.
Also see AWS Safety & Health Fact
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Generators.
Equipment Grounding Terminal (On
Front Panel)
Grounding Cable (Not Supplied)
3
Metal Vehicle Frame
frame. Always connect a ground
wire from the generator equipment
grounding terminal to bare metal on
the vehicle frame as shown.
Connect cable from equipment ground
terminal to metal vehicle frame. Use #8
AWG or larger insulated copper wire.
Electrically bond generator frame to vehicle frame by metal-to-metal contact.
!
Bed liners, shipping skids, and
some running gear insulate the
welding generator from the vehicle
!
Use GFCI protection when operating auxiliary equipment. If unit does
not have GFCI receptacles, use
GFCI-protected extension cord. Do
not use GFCI receptacles to power
life support equipment..
OM-255 254 Page 59
11-3. Grounding When Supplying Building Systems
1
2
1
Equipment Grounding
Terminal
Grounding Cable
Use #8 AWG or larger insulated
copper wire.
2
3
GND/PE
Ground Device
Use ground device as stated in
electrical codes.
2
3
!
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
ST-800 576-B
11-4. How Much Power Does Equipment Require?
1
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
3
2
1
Non-Resistive Load
Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running
(see Section 11-8).
VOLTS 115
AMPS 4.5
Hz
60
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.
3
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.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-255 254 Page 60
11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
11-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
OM-255 254 Page 61
11-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
OM-255 254 Page 62
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
11-8. Power Required To Start Motor
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
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
2
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.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624
11-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-255 254 Page 63
11-10. Typical Connections To Supply Standby Power
1
2
Utility
Electrical
Service
4
3
Transfer Switch
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
!
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
!
Properly install, ground, and
operate this equipment according to its Owner’s Manual and national, state, and local codes.
Customer-supplied equipment
is required if generator will supply standby power during
emergencies or power outages.
5
1 Utility Electrical Service
Essential
Loads
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is restored.
Install correct switch (customersupplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customersupplied) if required by electrical
code.
4 Welding Generator Output
Generator output voltage and wiring must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltage and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the premises. If generator does not produce
enough output to meet all requirements, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 11-4).
OM-255 254 Page 64
11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment.
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
Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
6
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-255 254 Page 65
SECTION 12 − PARTS LIST
Hardware is common and not
available unless listed.
Wiring harnesses are listed at
the end of parts section.
6
5
4
98
7
97
3
8
96
2
9
10
1
11
94
93
13
95
14
12
88
15
16
87
89
86
83
92
90
82
17
85
75
84
76
91
81
77
78
80
Figure 12-1. Main Assembly
OM-255 254 Page 66
79
26
28
27
24
25
23
22
36
35
29
21
30
20
34
33
32
31
19
18
64
65
67
66
37
38
39
63
54
55
74
62
61
40
53
60
73
41
72
57
71
58
59
50
56
52
42
43
46
44
45
51
47
38
49
68
48
69
70
255 254−1
OM-255 254 Page 67
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
. . . 1 . . . . . . . . . . Figure 12-2
. . . 2 . . . . . . . . . . . . . +243709
. . . . . . . . . . . . . . . . . . . . 256928
. . . 2 . . . . . . . . . . . ♦+249221
. . . 3 . . . . . . . . . . . . . . 213471
. . . 3 . . . . . . . . . . . . ♦213633
. . . 4 . . . . . . . . . . Figure 12-6
. . . 5 . . . . . . . . . . . . . . 213493
. . . 6 . . . . . . . . . . . . . . 189464
. . . 7 . . . . . . . . . . . . . . 214753
. . . 8 . . . . . . . . . . . . . . 209057
. . . 9 . . . . . . . . . . . . . . 212605
. . . 10 . . . . . . . . . . . . . . 254897
. . . 11 . . . . . . . . . . . . . . 212604
. . . 12 . . . . . . . . . . . . . . 213465
. . . 13 . . . . . . . . . . . . . . 190206
. . . 14 . . . . . . . . . . . . . . 190207
. . . 15 . . . . BATT . . . . 146237
. . . 16 . . . . . . . . . . . . . . 213466
. . . 17 . . . . . . . . . . . . . . 213464
. . . 18 . . . . . . . . . . . . . . 256249
. . . 19 . . . . . . . . . . . . . . 254899
. . . 20 . . . . . . . . . . . . . . 256928
. . . 21 . . . . . . . . . . . . . +249358
. . . 22 . . . . . . . . . . . . . . 222513
. . . 23 . . . . . . . . . . . . . . 189052
. . . 24 . . . . . . . . . . . . . . 254678
. . . 25 . . . . . . . . . . . . . . 192041
. . . 26 . . . . . . . . . . . . . . 249714
. . . 27 . . . . . . . . . . . . . . 224265
. . . 28 . . . . . . . . . . . . . . 214604
. . . 29 . . . . . . . . . . . . . . 248725
. . . . . . . . . . . . . . . . . . ♦249201
. . . 30 . . . . . . . . . . . . . . 213472
. . . 31 . . . . . . . . . . . . . . 212613
. . . 32 . . . . . . . . . . . . . +256613
. . . 33 . . . . . . . . . . . . . . 243698
. . . . . . . . . . . . . . . . . . . . 187120
. . . 34 . . . . . . . . . . . . . . 254901
. . . 35 . . . . . . . . . . . . . +243710
. . . 36 . . . . . . . . . . . . . . 243711
. . . 37 . . . . . . . . . . . . . . 220295
. . . 38 . . . . . . . . . . . . . . 225120
. . . 39 . . . . . . . . . . . . . . 255224
. . . 40 . . . . . . . . . . . . . . 222652
. . . 41 . . . . . . . . . . . . . . 249657
. . . . . . . . . . . . . . . . . . . . 197829
. . . . . . . . . . . . . . . . . . . . 249661
. . . . . . . . . . . . . . . . . . . *197676
. . . . . . . . . . . . . . . . . . . *197679
. . . . . . . . . . . . . . . . . . . . 249659
. . . . . . . . . . . . . . . . . . . . 249658
. . . . . . . . . . . . . . . . . . . . 249661
. . . 42 . . . . . . . . . . . . . . 203260
. . . 43 . . . . . . . . . . . . . . 239396
. . . 44 . . . . . . . . . . . . . . 168385
OM-255 254 Page 68
. . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Tape, Reflective (Heat) Must be ordered with Engine Side Panel . . . . .
. . Panel, Engine Side SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Cover Top (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Cover Top (LH) SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Weld Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pipe, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, Air Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bolt, J Stl .312−18 X 7.250 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . .
. . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . .
. . Battery, Stor 12v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Battery Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Gasket, Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pipe, Exhaust Flexible Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Tape, Reflective (Heat) Must be ordered with Top Cover . . . . . . . . . . . .
. . Cover, Top W/Protective Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . .
. . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . .
. . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cover, Radiator Access W/Protective Coating . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . .
. . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Cover Top (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket Cover Top (RH) SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Keeper, Latch Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Radiator Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Shroud, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Radiator, W/14# Cap 1 Row Core 1.250 Inlet/Outlet . . . . . . . . . . . . . . . . .
. . . . Cap, Radiator Pressure 14 Lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, Air Upper Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Upright, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Rear Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . .
. . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Air Cleaner, Intake 5.250 In (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Dust Ejector, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cover Assy, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Body, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Latch, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Diesel Engine Maintenance Mitsubishi S4L2 . . . . . . . . . . . . . . . . . .
. . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
3
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . . 45 . . . . . . . . . . . . . . 217698
. . . 46 . . . . . . . . . . . . . +248726
. . . . . . . . . . . . . . . . . ♦+249122
. . . 47 . . . . . . . . . . . . . . 245362
. . . . . . . . . . . . . . . . . . ♦190126
. . . . . . . . . . . . . . . . . . . . 191626
. . . 48 . . . . . . . . . . . . . . 248727
. . . . . . . . . . . . . . . . . . ♦249123
. . . 49 . . . . . . . . . . . . . . 249550
. . . 50 . . . . . . . . . . . . . . 252781
. . . 51 . . . . . . . . . . . . . . 254900
. . . 52 . . . . . . . . . . . . . . 241265
. . . 53 . . . . . . . . . . . . . . 199505
. . . . . . . . . . . . . . . . . . . . 165271
. . . . . . . . . . . . . . . . . . . . 176529
. . . . . . . . . . . . . . . . . . . . 113854
. . . 54 . . . . . . . . . . . . . . 212614
. . . 55 . . . . . . . . . . . . . . 256612
. . . 56 . . . . . . . . . . . . . . 213480
. . . 57 . . . . . . . . . . Figure 12-5
. . . 58 . . . . . . . . . . . . . . 213461
. . . 59 . . . . . . . . . . . . . . 213266
. . . 60 . . . . . . . . . . . . . . 023562
. . . 61 . . . . . . . . . . . . . . 113854
. . . 62 . . . . . . . . . . . . . . 256854
. . . 63 . . . . . . . . . . . . . . 256481
. . . 64 . . . . . . . . . . . . . . 256853
. . . 65 . . . . . . . . . . . . . . 010862
. . . 66 . . . . . . . . . . . . . . 255215
. . . . . . . . . . . . . . . . . . . . 202166
. . . . . . . . . . . . . . . . . . . . 213858
. . . . . . . . . . . . . . . . . . . . 217686
. . . . . . . . . . . . . . . . . . . . 217687
. . . . . . . . . . . . . . . . . . . . 214931
. . . . . . . . . . . . . . . . . . . . 217696
. . . . . . . . . . . . . . . . . . . . 204136
. . 67 . . . . . . . . . . . . . 256251
. . . 68 . . . . . . . . . . . . . . 227643
. . . 69 . . . . . . . . . . . . . . 181572
. . . 70 . . . . . . . . . . . . . . 189908
. . . 71 . . SENDER . . 235191
. . . 72 . . . . . . . . . . . . . . 124253
. . . 73 . . . . . . . . . . . . . . 212610
. . . 74 . . . . . . . . . . . . . . 212611
. . . 75 . . . . . . . . . . . . . . 213483
. . . 76 . . . . . . . . . . . . . . 213459
. . . 77 . . . . . . . . . . . . . . 213458
. . . 78 . . . . . . . . . . . . . . 213668
. . . 79 . . . . . . . . . . . . . . 224266
. . . 80 . . . . . . . . . . . . . . 233088
. . . 81 . . . . . . . . . . . . . . 213460
. . . 82 . . . . . . . . . . . . . . 213462
. . . 83 . . . . . . . . . . . . . . 213463
. . . 84 . . . . . . . . . . . . . . 192303
. . . 85 . . . . . . . . . . . . . . 213506
. . . 86 . . . . . . . . . . . . . . 190190
. . . 87 . . . . . . . . . . . . . . 213485
. . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Door, Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Door, Engine Access SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Latch, Paddle Series 20 (SS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Panel, Door Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Door Side SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose Assy, Oil Drain 32.000 Lg (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Ft.
. . Hose, Radiator Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Fan, Engine Cooling [390mm] 15.354 Dia. 6 Blade Pus . . . . . . . . . . . . . . . 0
. . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Clamp, Hose .312 - .875 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Hose, Sae .500 Id X .780 Od X coil . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.708 Ft.
. . Hose, Air Intake (Elbow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Tube, Intake Tee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Clamp,Hose 1.562 - 2.500 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Engine, Cat Dsl Elec C1.5 Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Filter, Oil Cat−220−1523 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Filter, Fuel In−Line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . 1
. . Belt, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Filter, Fuel Spin−On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Sender, Coolant Temp & 110c N.O. Switch . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Switch, Lubricating Oil Pressure N.O. (Perkins) . . . . . . . . . . . . . . . . . . . . . 1
. . Heater, Block Engine 120v 1000w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Mount, Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Tank, Fuel (Includes Fuel Cap And Items Below) . . . . . . . . . . . . . . . . . . . . 1
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Sender, Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) . . . . . . . . . . . . . . . . . . . . . 1
. . . . Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) . . . . . . . . . . . . . . . . . . . . . 1
. . Support, Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Crossmember, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Label, Danger Using A Generator Indoors Can Kill You In Minutes . . . . . 1
. . Crossmember, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pad, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spacer/Snubber, Generator Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Hold−Down Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Tank, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Support, Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-255 254 Page 69
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . . 88 . . . . . . . . . . . . . . 191307 . . Cover, Lower Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 89 . . . . . . . . . . . . . +226104 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 90 . . . . . . . . . . . . . . 233953 . . Label, Warning General Precautionary (CSA) (North America) . . . . . . . . .
. . . 90 . . . . . . . . . . . . . . 233952 . . Label,Warning General Precautionary Wordless (Export) . . . . . . . . . . . . .
. . . 91 . . . . . . . . . . . . . . 220955 . . Panel, Front Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 92 . . . . . . . . . . Figure 12-3 . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 93 . . . . CT1 . . . . 105370 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 94 . . TE1, TE2 . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 95 . . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 96 . . . . . . . . . . . . ♦244508 . . Pipe, Exhaust Spark Arresstor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 97 . . . . . . . . . . . . ♦088528 . . Spark Arrestor, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 98 . . . . . . . . . . . . ♦244507 . . Pipe, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 238650 . . Label, Hour/Fuel Meter Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts.
1
1
1
1
1
1
1
2
3
1
1
1
1
1
♦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-255 254 Page 70
Hardware is common and not
2
available unless listed.
3
Wirng harnesses are listed at
the end of parts section.
5
4
1
6
7
8
13
11
8
8
12
9
10
255 254−3
Figure 12-2. Control Panel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-2. Control Panel (Figure 12-1 Item 1)
... 1 ..............
... 2 ..............
. . . 3 . . . . . F1 . . . . .
. . . 4 . . . . CB1 . . . .
. . . 5 . . CR3 CR4 . .
. . . 6 . . . . CR1 . . . .
. . . 7 . . . R4, C4 . . .
. . . 8 . SR1,2,4,5,6 .
... 9 ..............
. . . 10 . . . . . . . . . . . . . .
. . . 11 . . . . CR2 . . . .
. . . 12 . . CB2, CB3 . .
. . . 13 . . . . . . . . . . . . . .
....................
285300
046432
085874
190374
197325
223710
249589
035704
222979
256695
214876
083432
129524
190323
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Dpst−no 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor/Capacitor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Mtg Governor Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Module, Control Governor (Programed) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 6vdc Spst 35a/14vdc 5 Pin (in Wiring Harness) . . . . . . . . . . .
Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . .
Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . .
Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
1
1
5
1
1
1
2
2
2
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-255 254 Page 71
7
6
5
Hardware is common and not
available unless listed.
8
Wiring harnesses are listed at
the end of parts section.
9
4
10
11
12
3
1
2
39
38
36
35
34
33
37
31
30
29
32
13
14
15
16
15
28
26
17
27
20 19
25
21
22
23
24
Figure 12-3. Panel, Front w/Components
OM-255 254 Page 72
18
255 254−4
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-3. Panel, Front w/Components (Figure 12-1 Item 92 )
... 1 ........................
. . . 2 . . . . . . . . . . . . . . 181169 . .
. . . 3 . . . . . . . . . . . . . . 255467 . .
. . . 4 . . . . PC6 . . . . 229949 . .
. . . 5 . . . . PC2 . . . . 247416 . .
. . . 6 . . . . . . . . . . . . . . 214543 . .
. . . 7 . . . . . . . . . . . . . . 134201 . .
. . . 8 . . . . . R1 . . . . . 246961 . .
. . . 9 . . . R2, R5 . . . 193118 . .
. . . 10 . . . . CB8 . . . . 083432 . .
. . . 11 . . . . . S4 . . . . . 021467 . .
. . . 12 . . . . . S1 . . . . . 217680 . .
. . . 13 . . . . . . . . . . . . . . 010381 . .
. . . 14 . . . . . . . . . . . . . . 241432 . .
. . . 15 . . GFCI1, 2 . . 246865 . .
. . . 16 . . C12, C13 . . 217054 . .
. . . 17 . . CB4, CB6 . . 093996 . .
. . . 18 . . . . CB5 . . . . 203026 . .
. . . 19 . . . . . . . . . . . . . . 601836 . .
. . . 20 . . . . . . . . . . . . . . 163167 . .
. . . 21 . . . . GRD . . . . 083030 . .
. . . 22 . . . . . . . . . . . . . . 010915 . .
. . . 23 . . . . . . . . . . . . . . 209056 . .
. . . 24 . . . . RC11 . . . . 182954 . .
. . . 25 . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . 186621 . .
. . . 27 . . . . . . . . . . . . . . 213509 . .
. . . 28 . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . C4, C5 . . . 128750 . .
. . . 30 . . . . . . . . . . . . . . 241433 . .
. . . 31 . . FUEL/HM . . 246181 . .
. . . 32 . . . . . . . . . . . . . . 180735 . .
. . . 33 . . . . . . . . . . . . . . 207073 . .
. . . . . . . . . . . . . . . . . . . . 201244 . .
. . . 34 . . . . . . . . . . . . . . 021385 . .
. . . 35 . . . . TEMP . . . 217084 . .
. . . 36 . . . . . . . . . . . . . . 218764 . .
. . . 37 . . . . . . . . . . . . . . 170391 . .
. . . 38 . . . . . . . . . . . . . . 190323 . .
. . . 39 . . . . . . . . . . . . . . 207079 . .
Nameplate (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure, Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . .
Switch, Rotary 8 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . . .
Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . .
Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . .
Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . .
Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . .
Supplementary Protector, Man Reset 2p 50a 240vac . . . . . . . . . . . . . . . . .
Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Lock .254idx0.489odx.062t Sst Split.250 . . . . . . . . . . . . . . . . . . .
Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . . .
Nameplate (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . .
Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Tooth.728idx1.166odx.050t Stl Pld Int.688 . . . . . . . . . . . . . . . . . .
Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge, Coolant Temp 0− 300 Deg F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer 1.625 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . .
Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer 1.125 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
4
1
2
1
1
1
2
1
2
2
2
1
3
2
1
4
4
1
1
2
1
1
2
1
1
2
1
1
1
1
1
1
2
2
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-255 254 Page 73
Hardware is common and not
available unless listed.
4
Wiring harnesses are listed at
the end of parts section.
6
7
3
9
8
5
2
1
10
11
14
13
12
Ref. 907 427-12A
Figure 12-4. Export Auxiliary Power Receptacles
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-4. Export Auxiliary Power Receptacles
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
. . . . RC11 . . . . 176355 . .
. . . . . . . . . . . . . . 206795 . .
........................
. . . . . . . . . . . . . . 239423 . .
. . . . . . . . . . . . . . 144844 . .
. . . ELCB1 . . . 222991 . .
. . . . CB5 . . . . 093996 . .
. . . GFCI1 . . . 246865 . .
. . . . . C11 . . . . 217054 . .
. . . . GRD . . . . 083030 . .
. . . . . . . . . . . . . . 010915 . .
. . . . . . . . . . . . . . 601836 . .
. . . . RC12 . . . . 173555 . .
. . . . . . . . . . . . . . 209056 . .
Rcpt, Str 2p3w 16a 220v Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . .
Panel, Power CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stand−off, No 6−32 X .875 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Elcb 16a 220v 0.030a Trip . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . .
Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . .
Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rcpt, Str 2p3w 16a 130v Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
4
1
1
1
1
1
4
3
1
2
♦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-255 254 Page 74
Hardware is common and not
7
available unless listed.
Wiring harnesses are listed at
the end of parts section.
8
6
5
4
3
1
2
11
9
10
255 254−5
Figure 12-5. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-5. Generator (Figure 12-1 Item 57)
... 1 ..............
... 2 ..............
. . . 3 . . STATOR . .
. . . 3 . . STATOR . .
....................
....................
....................
. . . 4 . . . ROTOR . . .
....................
....................
... 5 ..............
... 6 ..............
... 7 ..............
... 8 ..............
... 9 ..............
. . . 10 . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . .
183336
205725
257085
254327
183419
192686
602211
243820
181143
192600
243986
602216
256696
252956
212641
167788
136343
. . Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Brushholder Assy, Generator W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stator, Generator 4 Pole (Export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . O−ring, 1.984 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . .
. . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . .
. . Rotor, Generator 4 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . .
. . . . Fan, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, M12−1.25x 40 Hex Hd−pld Blk Grd 5 . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Lock .502idx0.879odx.151t Stl Pld Split.500 . . . . . . . . . . . . . . . .
. . Pickup, Magnetic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Adapter, Engine Machined Cat Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stud, Stl .375−16 1.625x 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . .
. . Screw, K50x 20 Pan Hd−phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . .
1
1
1
1
1
6
6
1
1
1
7
7
1
1
4
4
2
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-255 254 Page 75
Hardware is common and not
11
available unless listed.
Wiring harnesses are listed at
the end of parts section.
1
12
2
13
3
4
5
6
7
14
8
9
10
17
16
15
246 580-1A
Figure 12-6. Weld Control Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-6. Weld Control Assembly 246 580 (Figure 12-1 Item 4)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
. . MOD1, 2 . .
..............
..............
..............
..............
..............
..............
. . . . . C1 . . . . .
..............
. . . . . R3 . . . . .
. . . . PC1 . . . .
..............
. . . . SR3 . . . .
. . . . . Z1 . . . . .
OM-255 254 Page 76
247407
245359
247091
247093
245378
247092
089178
246841
239547
188067
246330
245360
225516
248548
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Heat Sink, IGBT Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator ,Buss Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stand−off, Conductive Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Buss Bar, AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grommet, Rbr 3.000 Id X 3.500 Mtg Hole .062 Groove . . . . . . . . . . . . . . .
Capacitor, Elctlt 35000 Uf 100 Vdc Can 3.00 Dia . . . . . . . . . . . . . . . . . . . . .
Washer, Flat Nylon .516 Id X 1.250 Od X .062 Thk . . . . . . . . . . . . . . . . . .
Resistor, Ww Fxd 00 W 200 Ohm W/Clips . . . . . . . . . . . . . . . . . . . . . . . . .
Module, Main Control/IGBT Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Mtg Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier, Si 3ph 300 Amp 400 Piv 100% Duty Cycle . . . . . . . . . . . . . . . . .
Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
4
1
1
2
2
2
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-6. Weld Control Assembly 246 580 (Figure 12-1 Item 4)
. . . 15 . . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 245361 . . Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . T1 . . . . . 247224 . . Xfmr,Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-255 254 Page 77
Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness.
Dia.
Mkgs.
Part
No.
Description
Quantity
Wiring Harnesses
....................
. . . . . . . . . . . S4 . . . . .
. . . . . . . . SR1−SR2 . .
. . . . . . . . . . CB1 . . . .
. . . . . . . . CB2−CB3 . .
. . . . . . . . . . CR3 . . . .
. . . . . . . . . . CR2 . . . .
. . . . . . . . . . CR4 . . . .
ACTUATOR,S2−S3,
TEMP SENDER
....................
. . . . . . . . . . PLG6 . . . .
....................
....................
....................
. . . . . . . . . . . J1 . . . . .
....................
....................
....................
. . . . . . . L1−L2,L4−L5
. . . . . . . . . . . J2 . . . . .
....................
....................
....................
....................
. . . . . . . . . PLG18 . . .
....................
255198 . . Harness, Engine Cat 1.5 Turbo (includes) . . . . . . . . . . . . . . . . . . . . . . . .
021467 . . . Switch, Tgl Spst 3a 250v Off−None−(On) Spd Term . . . . . . . . . . . . . . .
035704 . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . .
190374 . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . .
083432 . . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . .
197325 . . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . .
252053 . . . Relay, Encl 12vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . .
148850 . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
2
1
1
1
212116 . . . . Conn, Deutsch 2p 1row Female Plug
212117 . . . . Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . .
214932 . . . Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . .
214933 . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147995 . . . Conn, Rect Univ 039 Skt 22−18ga .094od Gold . . . . . . . . . . . . . . . . . . .
255333 . . . Harness, Governor Control Cat Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . .
218798 . . . . . Conn, Deutsch Dtm 12p 2row Plug ’A’ . . . . . . . . . . . . . . . . . . . . . . . . . .
218800 . . . . . Conn, Deutsch Dtm Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . .
212116 . . . . . . Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . .
212117 . . . . . . Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . .
204702 . . . . . Core, Toroidal .187 Id X .375 Od X .125 Thk . . . . . . . . . . . . . . . . . . . .
218799 . . . . . Conn, Deutsch Dtm 12p 2row Plug ’B’ . . . . . . . . . . . . . . . . . . . . . . . . . .
255377 . . . . . Cable, Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
255207 . . . . . Conn, Deutsch 2p 1row Female Plug Dtm Series . . . . . . . . . . . . . . . . .
255208 . . . . . Conn, Deutsch Wedge Lock 2 Pos Dtm Series . . . . . . . . . . . . . . . . . .
177859 . . . Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
255207 . . . Conn, Deutsch 2p 1row Female Plug Dtm Series . . . . . . . . . . . . . . . . . .
255208 . . . Conn, Deutsch Wedge Lock 2 Pos Dtm Series . . . . . . . . . . . . . . . . . . . .
4
4
1
7
7
1
1
2
1
1
4
1
1
1
1
1
1
1
....................
....................
....................
....................
....................
222687
093996
246865
217054
214918
.
.
.
.
.
Harness, Receptacle Auxilary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . .
Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . .
Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
2
1
....................
. . . . . . . PLG2,PLG9 .
. . . . . . . . . . PLG3 . . . .
....................
....................
....................
. . . . . . . . . . PLG6 . . . .
. . . . . . PLG7,PLG11
. . . . . . . . . . PLG5 . . . .
....................
. . . . . . . . . . PLG4 . . . .
....................
. . . . . . . . . . PLG8 . . . .
. . . . . . . . . . RC3 . . . .
. . . . . . PLG10,PLG15
. . . . . . . . . C4/R4 . . .
248797 .
150316 .
214951 .
214933 .
214934 .
235021 .
193184 .
193183 .
113750 . .
217000 .
215340 .
196602 .
231708 .
155129 .
113751 . .
249589 .
Harness, Weld Control Cat 1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal . . . . . . . . . . . . . . . .
Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . .
Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg . . . . . . . . . . . . . . . . . .
Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . .
Conn, Rect Univ 039 6p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . .
Conn, Rect Mini 045 8skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . .
Resistor/Capacitor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
15
7
1
1
2
1
1
1
17
1
1
2
1
OM-255 254 Page 78
Notes
OM-255 254 Page 79
Notes
OM-255 254 Page 80
Effective January 1, 2012
(Equipment with a serial number preface of MC or newer)
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.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions 6. 90 Days — Parts
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its
* Accessory (Kits)
original retail purchaser that new Miller equipment sold after the
* Canvas Covers
effective date of this limited warranty is free of defects in material
* Induction Heating Coils and Blankets, Cables, and
and workmanship at the time it is shipped by Miller. THIS
Non-Electronic Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* M-Guns
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* MIG Guns and Subarc (SAW) Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Remote Controls and RFCS-RJ45
Within the warranty periods listed below, Miller will repair or replace
* Replacement Parts (No labor)
any warranted parts or components that fail due to such defects in
* Roughneck Guns
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
* Spoolmate Spoolguns
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 delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to an
International distributor.
1.
2.
3.
4.
5.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Engine Driven Welding Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith 30 Series Flowgauge and Flowmeter
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or
for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
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.
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 2012-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
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.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2012 Miller Electric Mfg. Co.
2012−01
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