Miller BIG BLUE 500 X (PERKINS) User manual

Miller BIG BLUE 500 X (PERKINS) User manual
OM-4421
215 075Y
2010−03
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
Big Blue 400P
Big Blue 500 X CE
(Perkins-Powered)
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 Quality System Warranty and service information for your
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. Hydraulic Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-9. 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’hydraulique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-7. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions (For Wordless Labels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. 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. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Volt-Ampere Curves For CC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Volt-Ampere Curves For CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Optional Three-Phase Generator Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models . . . . . . . . . . . . . . . . . . . . .
5-13. Connecting To Remote 14 Receptacle RC14 On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls For CC Models (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Remote Amperage Control On CC Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Weld Control/Arc Condition Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Front Panel Controls For CC/CV Models (See Section 7-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) . . . . . . . . . . . . . . . . . . . . . .
7-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Domestic Auxilary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Export Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5. Inspecting/Cleaning Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-7. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-8. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-9. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
36
36
37
38
39
40
41
41
42
43
44
44
45
46
47
48
49
50
51
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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
Stock Number
Big Blue 500X CC CE
Big Blue 500X CC/CV CE
907187
907186
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)
US Signatory:
August 31, 2009
________________________________________________________________
David A. Werba
MANAGER, PRODUCT DESIGN COMPLIANCE
245811­A
Date of Declaration
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2009−10
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 1-8. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also live
when power is on. In semiautomatic or automatic wire
welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically
live. Incorrectly installed or improperly grounded
equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground — check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
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.
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-4421 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.
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
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.
BUILDUP OF GAS can injure or kill.
Noise from some processes or equipment can damage hearing.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
Wear approved ear protection if noise level is
high.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
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-4421 Page 2
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.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process, be
sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, 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 shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
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.
BATTERY CHARGING OUTPUT can injure.
(Battery charging feature not present on all models.)
Have only qualified persons do battery charging work.
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 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.
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.
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.
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.
OM-4421 Page 3
1-4. Hydraulic Hazards
HYDRAULIC 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 hydraulic pump
or any equipment in the hydraulic system. Design hydraulic system so failure of any hydraulic component will not put people or
property at risk.
Before working on hydraulic system, turn off and lockout/tagout
unit, release pressure, and be sure hydraulic pressure cannot be
accidentally applied.
Do not work on hydraulic system with unit running unless you are
a qualified person and following the manufacturer’s instructions.
Do not modify or alter hydraulic pump or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the hydraulic system.
Use only components/accessories approved by the manufacturer.
Keep away from potential pinch points or crush points created by
equipment connected to the hydraulic system.
Do not work under or around any equipment that is supported
only by hydraulic pressure. Properly support equipment by
mechanical means.
HYDRAULIC FLUID can injure or kill.
Before working on hydraulic system, turn off and
lockout/tagout unit, release pressure, and be sure
hydraulic pressure cannot be accidentally applied.
Relieve pressure before disconnecting or connecting hydraulic lines.
Check hydraulic system components and all connections and hoses for damage, leaks, and wear
before operating unit.
Wear protective equipment such as safety
glasses, leather gloves, heavy shirt and trousers,
high shoes, and a cap when working on hydraulic
system.
Use a piece of paper or cardboard to search for leaks−−never use
bare hands. Do not use equipment if leaks are found.
HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics
near sparks or flames; do not smoke near hydraulic fluid.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
If ANY fluid is injected into the skin, it must be surgically removed
within a few hours by a doctor familiar with this type of injury or gangrene may result.
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 hydraulic system, turn off and lockout/tagout
unit, release pressure, and be sure hydraulic 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 AND FLUID can burn.
Do not touch hot parts bare handed or allow hot
fluid to contact skin.
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. 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.
OM-4421 Page 4
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.
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.
1-6. 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.
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.
OM-4421 Page 5
WELDING WIRE can injure.
H.F. RADIATION can cause interference.
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.
STATIC (ESD) can damage PC boards.
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.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
TILTING OF TRAILER can 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.
Electromagnetic energy can interfere with
sensitive electronic equipment such as microprocessors, computers, and computer-driven
equipment such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-7. 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.
OM-4421 Page 6
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.
1-8. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
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).
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, 4221 Walney Road, 5th Floor,
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.
For Standards about hydraulic systems, contact the National Fluid
Power Association, Publications Department, 3333 North Mayfair
Road, Suite 211, Milwaukee, WI 53222-3219 (phone: (414) 778-3344,
website: www.nfpa.com).
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).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.gov).
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).
1-9. 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, access restrictions for passers−by or 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.
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.
OM-4421 Page 7
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
fre_rom_2009−10
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 2-8. 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
OM-4421 Page 8
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas travailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à
l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
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.
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.
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 (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.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
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.
Fermer l’alimentation du gaz protecteur en cas
de non utilisation.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
Veiller toujours à bien aérer les espaces confinés ou se servir
d’un respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le 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.
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.
OM-4421 Page 9
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 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 protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
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.
Ranger les câbles de charge à distance du capot, des portes et
des pièces mobiles du véhicule.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
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.
Le COURANT DE CHARGE DE BATTERIE peut
provoquer des blessures (la fonctionnalité de charge de
batterie n’est pas disponible sur tous les modèles).
Les opérations de charge de batterie ne doivent être effectuées
que par des personnes qualifiées.
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.
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.
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,
recouvrements et dispositifs de protection.
panneaux,
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.
Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien, débrancher le câble négatif (−) de batterie de la borne.
Ne pas utiliser de câbles de charge endommagés.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Ne pas charger une batterie dont les bornes sont desserrées ou
présentant une détérioration comme par exemple un boîtier ou un
couvercle fissuré.
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 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.
OM-4421 Page 10
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.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.
Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
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.
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’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.
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.
2-4. Dangers liés à l’hydraulique
Les ÉQUIPEMENTS HYDRAULIQUES
peuvent 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, faire fonctionner
et réparer 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 de la pompe
hydraulique ou de tout équipement du circuit hydraulique.
Concevoir le circuit hydraulique de telle sorte que la défaillance
d’un composant hydraulique ne risque pas de provoquer
un accident matériel ou corporel.
Avant d’intervenir sur le circuit hydraulique, couper l’alimentation
électrique, verrouiller et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit hydraulique ne peut être remis sous
pression par inadvertance.
Ne pas intervenir sur le circuit hydraulique lorsque l’appareil
fonctionne. Seul un personnel qualifié et appliquant les consignes
du fabricant est autorisé le faire.
Ne pas modifier ou altérer la pompe hydraulique ou
les équipements fournis par le fabricant. Ne pas débrancher,
désactiver ou neutraliser les équipements de sécurité du circuit
hydraulique.
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
hydraulique.
Ne pas intervenir sous ou autour d’un équipement qui n’est
soutenu que par la pression hydraulique. Soutenir l’équipement
de façon appropriée par un moyen mécanique.
Le LIQUIDE HYDRAULIQUE risque de
provoquer des blessures ou même la mort.
Avant d’intervenir sur le circuit hydraulique,
couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit hydraulique ne peut
être remis sous pression par inadvertance.
Détendre la pression avant de débrancher ou
de brancher des canalisations hydrauliques.
Avant
d’utiliser
l’appareil,
contrôler
les composants du circuit hydraulique,
les branchements et les flexibles en recherchant
tout signe de détérioration, de fuite et d’usure.
Pour intervenir sur un circuit hydraulique, 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 un morceau de papier ou
de carton, jamais les mains nues. En cas de détection de fuite,
ne pas utiliser l’équipement.
Le LIQUIDE HYDRAULIQUE est INFLAMMABLE. Ne pas
intervenir sur des composants hydrauliques à proximité
d’étincelles ou de flammes; ne pas fumer à proximité de liquide
hydraulique.
Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
En cas de pénétration d’un QUELCONQUE liquide dans la peau,
celui−ci doit être retiré chirurgicalement sous quelques heures par
OM-4421 Page 11
un médecin familiarisé avec ce type de blessure, faute de quoi
la gangrène pourrait apparaître.
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 hydraulique, couper l’alimentation
électrique, verrouiller et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit hydraulique ne peut être remis 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.
LES PIÈCES ET LIQUIDES CHAUDS
peuvent provoquer des brûlures.
Ne pas toucher les pièces chaudes à main nue
ni laisser des liquides chauds entrer en contact
avec la peau.
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 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.
OM-4421 Page 12
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.
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.
2-6. 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.
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-4421 Page 13
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.
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.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
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.
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.
2-7. 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.
2-8. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
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).
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, 4221 Walney Road, 5th Floor,
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).
OM-4421 Page 14
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.
For Standards about hydraulic systems, contact the National Fluid
Power Association, Publications Department, 3333 North Mayfair
Road, Suite 211, Milwaukee, WI 53222-3219 (phone: (414) 778-3344,
website: www.nfpa.com).
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, Super-
intendent 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).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.gov).
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).
2-9. 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-4421 Page 15
SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions (For Wordless Labels)
S-177 571
1
+
2
2
3
+
3
1
4
DIESEL
5
4
6
5
7
0 − 50 h Std.
200A
Remove unit from shipping
crate. Remove Owner’s
Manual from unit. Follow
instructions to install muffler.
Read Owner’s Manual. Read
labels on unit.
Use Diesel Fuel only, and fill
fuel tank. Leave room for
expansion.
Warning! Watch Out! There
are possible hazards as
shown by the symbols. Read
Owner’s Manual. Follow
instructions to activate
battery.
Check oil level. Add oil if
necessary.
During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
After the first 50 hours of
operation, change the oil and
oil filter.
0 − 200A
50 h Std.
API CD-MIL L 2104D,
CD/SE, CD/SF
3/96
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4421 Page 16
3-2. Symbols And Definitions
Some symbols are found only on export products.
A
Stop Engine
Fast (Run, Weld/
Power)
Slow (Idle)
Start Engine
Starting Aid
Battery (Engine)
Engine Oil
Pressure
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
Panel/Local
Remote
Engine
Air Temperature Or
Engine
Temperature
Output
Alternating
Current
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
TIG (GTAW)
Amperes
Time
3
V
h
Hours
Three Phase
Read Operator’s
Manual
Electrode
Connection
Work Connection
s
Seconds
1
Single Phase
Do Not Switch
While Welding
Circuit Protector
G
3
Engine-Driven,
Three-Phase
Alternator With
Rectifier
X
Duty Cycle
U0
Rated No Load
Voltage (Average)
U2
Conventional
Load Voltage
n1
Rated Idle
Speed
n0
Rated No Load
Speed
I
Current
Hz
n
I2
Hertz
Rated Load
Speed
Rated Welding
Current
Contactor On
OM-4421 Page 17
SECTION 4 − SPECIFICATIONS
4-1. Important Information Regarding CE Products (Sold Within The EU)
!
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.
4-2. Weld, Power, And Engine Specifications
Welding
Mode
CC/DC
Weld Output
Range
55 − 500 A
(CC Models)
15 − 500 A
(CC/CV Models)
Rated Welding
Output
Maximum
OpenCircuit
Voltage
430 A, 37 Volts DC,
60% Duty Cycle
95
300 A, 29 Volts DC
(CV),100% Duty Cycle
14 − 40 V
OM-4421 Page 18
450 A, 38 Volts DC,
60% Duty Cycle
500 A,
30 Volts DC (CC),
34 Volts DC (CV),
40% Duty Cycle
Standard
Single-Phase,
4 kVA/kW, 34/17 A,
120/240 V AC,
50/60 Hz
Fuel
Capacity
Perkins
Three-Phase Generator
Perkins 404D-22
Option*
Water-Cooled,
Single-Phase/Three-Phase,
Four-Cylinder,
12/15 kVA/kW, 50/36A,
32.6 HP Diesel Engine
120/240 VAC, 60 Hz
Other Models:
400 A, 36 Volts DC,
100% Duty Cycle
CV/DC
Engine
Export Models:
300 A, 32 Volts DC,
100% Duty Cycle
430 A, 36 Volts DC
(CV), 60% Duty Cycle
(CC/CV
Models
Only)
Generator Power
Rating
56
*In Addition To Standard
4 kVA/kW Generator Power
25 gal
(95 L)
4-3. Dimensions, Weights, And Operating Angles
Dimensions
60 in (1524 mm)
(to top of muffler)
Height
Width
*
G
28-1/2 in (724 mm)
(mtg. brackets turned in)
30-3/4 in (781 mm)
(mtg. brackets turned out)
Depth
65-1/8 in (1654 mm)
!
A
65-1/8 in (1654 mm)
Do not exceed tilt angles or engine could
be damaged or unit could tip.
B*
56 in (1422 mm)
!
Do not move or operate unit where it could
tip.
C*
46-1/2 in (1181)
D*
9-5/8 in (244 mm)
E
27-1/2 in (699 mm)
F
1 in (25 mm)
G
29-13/16 in (757 mm)
H
9/16 in (14 mm) Dia.
4 Holes
A
B
C
30°
H
30°
20°
D
With mounting brackets in center
position. Dimensions vary with
location of mounting brackets.
F
Weight
w/ Perkins
404-22
20°
E
No fuel: 1600 lb (726 kg)
W/fuel: 1775 lb (805 kg)
802 161-A
Lifting Eye Weight Rating:
2500 lb (1134 kg) Maximum
4-4. Volt-Ampere Curves For CC Models
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
100
Ranges:
230 − Max
170 − 365
110 − 225
70 − 130
55 − 85
DC VOLTS
80
60
40
20
0
0
100
200
300
400
500
600
700
800
900 1000
DC AMPERES
215 081-A
OM-4421 Page 19
4-5. Volt-Ampere Curves For CC/CV Models
A. Stick Mode
100
RANGES:
MAX
155 − 450
115 − 320
75 − 195
40 − 90
80
DC VOLTS
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
40
20
0
0
100
200
300
400 500 600
DC AMPERES
700
800
900 1000
400
700
800
900 1000
B. MIG Mode
100
80
DC VOLTS
60
MAX
40
20
MIN
0
0
100
200
300
500
600
DC AMPERES
C. TIG Mode
100
RANGES:
60 − 365
35 − 250
25 − 155
15 − 75
DC VOLTS
80
60
40
20
0
0
OM-4421 Page 20
100
200
300
DC AMPERES
400
500
215 080-A / 215 083-A / 215 079-A
4-6. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
2.50
2.25
2.00
US Gal./Hr.
1.75
1.50
1.25
1.00
0.75
0.50
IDLE
0.25
0.00
0
50
100 150 200 250 300 350 400 450
DC WELD AMPERES AT 100% DUTY CYCLE
500
199 032−A
4-7. Duty Cycle And Overheating
100% Duty Cycle At 400 Amperes
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Continuous Welding
215 084-A
OM-4421 Page 21
4-8. AC Generator Power Curve
The ac power curve shows the generator power in amperes available
at the 120 and 240 volt receptacles.
150 300
AC VOLTS
125 250
100 200
75 150
50 100
25
50
0
0
0
5
10
15
20
AC AMPERES IN 240V MODE
10
20
30
40
AC AMPERES IN 120V MODE
0
25
30
50
60
193 018
4-9. Optional Three-Phase Generator Curves
A. 12 kVA/kW Single-Phase AC Output (No Weld Load)
280
The ac power curves show the generator power available in amperes
at the single-phase 120/240 volt receptacle or three-phase 240 volt
terminals.
AC VOLTS
260
240
220
200
180
0
10
20
30 40 50 60
AC AMPERES
70
80
90 100
B. 15 kVA/kW Three-Phase AC Output (No Weld Load)
280
AC VOLTS
260
240
220
200
180
0
10
20
30
40
AC AMPERES
OM-4421 Page 22
50
60
70
215 086-A / 215 087-A
SECTION 5 − INSTALLATION
5-1. Serial Number And Rating Label Location
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 4-3 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-4421 Page 23
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-4421 Page 24
5-4. Grounding Generator To Truck Or Trailer Frame
1
!
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.
!
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
1
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
2
GND/PE
2
3
3
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
Electrically
bond generator
frame to vehicle frame by metal-to-metal contact.
rot_grnd 2008-01 − 800 652-D
5-5. Using Lifting Eye
1
2
3
1
Lifting Eye
Nut
Carriage Bolt
Raise lifting eye until it snaps in
place. Lower lifting eye when not
needed.
2
To lock the lifting eye in the upright
position, insert a 3/8-16 x 1-1/2 in
carriage bolt through slot in bracket
and secure with nut (bolt and nut not
supplied).
Tools Needed:
3
Lift1 2008−01 804 712
OM-4421 Page 25
5-6. 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
Notes
OM-4421 Page 26
Exhaust1 2008−01 Ref. 803 604 / Ref. 236 972
5-7. Activating The Dry Charge Battery (If Applicable)
!
3
Always wear a face shield,
rubber gloves and protective
clothing when working on a
battery.
Remove battery from unit.
1
2
2
1
3
Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
Well
Fill each cell with electrolyte to
bottom of well (maximum).
!
Do not overfill battery cells.
Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
4
Battery Charger
!
Read and follow all instructions supplied with battery
charger.
5
5 Amperes For 30 Minutes
Charge Time
30 Amperes For 12 Minutes
Charge Time
6
5
4
Charge battery. Disconnect charging cables and install battery.
When electrolyte
is low, add
only distilled water to cells to
maintain proper level.
5A
+
6
−
Tools Needed:
30 A
drybatt1 2008−01 − S-0886
5-8. Connecting The Battery
!
Connect negative (−) battery
cable last.
Reinstall cover after connecting battery.
+
−
Tools Needed:
1/2 in
Conn_batt1 2008−02 802 168-E / Ref. 202 705 / 802 313 / S-0756-C
OM-4421 Page 27
5-9. Engine Prestart Checks
Check radiator coolant
level when fluid is low in
recovery tank.
Full
Capacity:
404.22 Engine: 9.5 qt (9.01L)
Full
Diesel
Full
Coolant Recovery Tank
Hot Full
Cold Full
803 603
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 or coolant temperature is too high.
This unit has a low oil pressure shut-
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 11.
Fuel
NOTICE − Do not use gasoline. Gasoline
will damage engine.
The unit is shipped with enough fuel to prevent air from entering fuel system. Add fresh
diesel fuel before starting (see engine maintenance label for fuel specifications). Leave
filler neck empty to allow room for expansion.
OM-4421 Page 28
After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Coolant
Check coolant level in radiator before starting unit the first time. If necessary, add coolant to radiator until coolant level is at bottom
of filler neck.
Check coolant level in recovery tank daily.
If necessary, add coolant to recovery tank
until coolant level is between Cold Full and
Hot Full levels. If recovery tank coolant level
was low, also check coolant level in radiator.
Add coolant if level is below bottom of radiator filler neck.
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 Starting Aid switch (see Section
6-1 or 7-1).
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 9-1).
5-10. Connecting To Weld Output Terminals
Stick and TIG Welding
For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect electrode
holder cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on right.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional Polarity switch or optional Polarity/AC switch, connect electrode
holder cable to Electrode (+) terminal on left
and work cable to Work (−) terminal on right.
!
Stop engine.
!
Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
MIG and FCAW Welding
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP) on CC/CV models,
connect wire feeder cable to Positive (+) terminal on left and work cable to Negative (−) terminal on right. Use Process/Contactor switch
to select type of weld output (see Section 7-3).
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional Polarity switch or optional Polarity/AC switch, connect wire feeder
cable to Electrode (+) terminal on left and
work cable to Work (−) terminal on right.
Do not place anything between weld cable
terminal and copper bar. Make sure that
the surface of the weld cable terminal and
copper bar are both 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.
7
Positive (+) Weld Output Terminal
8
Negative (−) Weld Output Terminal
7
8
Tools Needed:
2
1
3
3/4 in
6
4
5
803 602 / 803 778-B
OM-4421 Page 29
5-11. 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
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
!
!
Stop engine before
connecting to weld
output terminals.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
10 − 100% Duty Cycle
Do not use worn, damaged, undersized, or
poorly spliced cables.
* This
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-G 2009−08
5-12. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models
1
1
Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
RC13 (see Section 6-3).
Ref. 154 862-A / 048 720-K / 803 602
OM-4421 Page 30
5-13. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
Socket*
Socket Information
A
24 volts AC. Protected by supplementary protector CB5.
B
Contact closure to A completes
24 volt AC contactor control
circuit.
C
Output to remote control:+10
volts DC in MIG or Stick mode;
0 to +10 volts DC in TIG mode.
D
Remote control circuit common.
E
DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
24 VOLTS AC
REMOTE
OUTPUT
CONTROL
I
115 volts, 10 amperes, 60 Hz
AC. Protected by supplementary protector CB6.
J
Contact closure to I completes
115 volt AC contactor control
circuit.
GND
K
Chassis common.
NEUTRAL
G
Circuit common for 24 and 115
volt AC circuit.
115 VOLTS AC
OR
Ref. 803 602
*The remaining sockets are not used.
Notes
Start Your Professional
Welding Career Now!
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
Over 80,000 trained
since 1930!
OM-4421 Page 31
SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS
6-1. Front Panel Controls For CC Models (See Section 6-2)
7
6
11
12
5
3
4
13
8
9
1
2
10
236 970 / 803 602
OM-4421 Page 32
6-2. Description Of Front Panel Controls For CC Models (See Section 6-1)
Engine Starting Controls
1 Starting Aid Switch
Use switch to energize starting aid for cold
weather starting (see starting instructions following).
2 Engine Control Switch
Use switch to start and stop engine.
To Start:
NOTICE − Do not use ether. Using ether
voids warranty.
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): push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.
To Stop: turn Engine Control switch to Off
position.
Engine Gauges And Meters
3 Engine Fuel/Hour Gauge
Use gauge to monitor engine running time for
scheduling maintenance and to determine
cause of engine shutdowns.
Use gauge to check fuel level. Engine stops
if fuel level is low.
To check fuel level when engine is not running, turn Engine Control switch to Run position.
See Section NO TAG for complete fuel/hour
gauge information.
4 Engine Oil Pressure Gauge (Optional)
Normal pressure is 30 − 60 psi (207 − 414
kPa). Engine stops if pressure is below 10 psi
(69 kPa).
5 Engine Coolant Temperature Gauge
(Optional)
Normal temperature is 180 - 203° F (82 - 95°
C). Engine stops if temperature exceeds 220°
F (104° C).
Weld Controls
When switch is in the Stick position, the max
OCV circuit resets Amperage Adjust Control
R1 to maximum when the arc breaks.
Max OCV Control Circuit: This unit has
When switch is in Scratch Start TIG position,
the max OCV and arc drive (dig) circuits are
disabled and OCV changes when the control
is adjusted.
a max OCV control circuit that resets Amperage Adjust control R1 to maximum
when the arc breaks. When an arc is
struck, weld output control returns to the
R1 front panel or combination front panel/
remote control setting. The Amperage
Adjust control adjusts amperage only
when welding and does not adjust opencircuit voltage.
The max OCV circuit is disabled when
the Stick/TIG Selection switch is in
Scratch Start TIG position (see item 8).
Also in the Stick position, the arc drive (dig)
circuit provides additional amperage during
low voltage (short arc length conditions) to
prevent “sticking” electrodes.
9
Amperage Adjust Switch And Remote
Amperage Adjust Receptacle
Connect optional remote control to RC13
(See Section 5-12). Use switch to select front
panel or remote amperage control. For remote control, place switch in Remote position
and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 5-12 and 6-3).
10 Polarity Switch (Optional)
6 Ampere Range Switch
NOTICE − Do not switch under load.
Use switch to select weld amperage range.
For most welding applications, use lowest
amperage range possible to help prevent arc
outages.
7 Amperage Adjust Control
Control adjusts amperage within range selected by Ampere Range switch. Weld output
would be about 168 A DC with controls set as
shown (50% of 110 to 225 A).
NOTICE − Do not switch under load.
The numbers around the control are for
Ammeter displays amperage output of the
unit.
13 Battery Voltmeter (Optional)
Use gauge to check battery voltage and monitor engine charging system. The meter
should read about 14 volts DC when the engine is running and about 12 volts DC when
the engine is stopped.
reference only and do not represent an
actual percentage value.
8 Stick/TIG Selection Switch
Use switch to disable the max OCV circuit
and the arc drive (dig) circuit for scratch start
TIG welding (see max OCV note under Weld
Controls).
Use switch to change weld output. Select either DC Electrode Positive (DCEP) or DC
Electrode Negative (DCEN).
Weld Meters
11 AC/DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
12 AC/DC Ammeter (Optional)
OM-4421 Page 33
6-3. Remote Amperage Control On CC Models (Optional)
1
Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
RC13 (see Section 5-12).
1
In Example:
Range = 110 to 225 A DC
Percentage Of Range = 50%
Max = About 168 A DC (50% of 110 to 225)
Example: Combination Remote Amperage Control (Stick)
Max (168 A DC)
Min (90 A DC)
Set Switches
Set Range
Set Control
Adjust Optional Remote Control
Ref. 154 862-A / Ref. 181 711-A / 803 602
6-4. Weld Control/Arc Condition Information Label
Set weld controls as shown to
achieve softer or stiffer arc conditions for different applications.
212 944-B
OM-4421 Page 34
Notes
WELD POSITION: FLAT
WELD JOINT
TYPES
HORIZONTAL
BUTT
1G
VERTICAL
BUTT
2G
FILLET
Ref. AWS/ANSI D1.1
T−JOINT
1F
BUTT
4G
BUTT
3G
T−JOINT
2F
GROOVE
OVERHEAD
T−JOINT
4F
T−JOINT
3F
Ref. 804 248-A
OM-4421 Page 35
SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS
7-1. Front Panel Controls For CC/CV Models (See Section 7-2)
6
13
12
7
5
4
3
14
2
1
8
11
9
10
OR
236 971 / 803 602
OM-4421 Page 36
7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)
Engine Starting Controls
1
Starting Aid 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 ( if unit has auto idle option), and stop
engine.
In Run position, engine runs at weld/power
speed. In Run/Idle position (optional), engine
runs at idle speed at no load and weld speed
with load applied.
4
Engine Coolant Temperature Gauge
(Optional)
Normal temperature is 180 - 203° F (82 - 95°
C). Engine stops if temperature exceeds 220°
F (104° C).
5
Engine Oil Pressure Gauge (Optional)
Normal pressure is 30 − 60 psi (207 − 414
kPa). Engine stops if pressure is below 10 psi
(69 kPa).
Weld Controls
6
Process/Contactor Switch
!
Use AC output ONLY if required for the
welding process. If AC output is required, use remote output control if
present on unit.
NOTICE − Do not switch under load.
Ampere Range Switch
Use the highest range for MIG welding and for
cutting and gouging (CAC-A).
For most welding applications, use lowest
amperage range possible to help prevent arc
outages.
8
Voltage/Amperage Adjust Control
Use gauge to monitor engine running time for
scheduling maintenance and to determine
cause of engine shutdowns.
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage
within range selected by Ampere Range
switch. With Process/Contactor switch in any
MIG position, use control to adjust voltage.
With Voltage/Amperage Adjust Switch in Remote position, control limits the remote amperage in TIG mode, but has no effect in Stick
and MIG modes.
Use gauge to check fuel level. Engine stops
if fuel level is low.
Weld output would be about 218 A DC with
controls set as shown (50% of 115 to 320 A).
To check fuel level when engine is not running, turn Engine Control switch to Run or
Run/Idle position.
The numbers around the control are for
reference only and do not represent an
actual percentage value.
See Section NO TAG for complete fuel/hour
gauge information.
9
To Stop: turn Engine Control switch to Off
position.
Engine Gauges And Meters
3
Engine Fuel/Hour Gauge
11 Polarity/AC Switch (Optional)
Use the lowest four ranges for Stick and TIG
welding. Read the upper set of numbers at
each range for Stick welding and the lower set
at each range for TIG welding.
NOTICE − Do not switch under load.
Below 325 F (05 C): push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.
Use Polarity switch to change weld output.
Select either DC Electrode Positive (DCEP)
or DC Electrode Negative (DCEN).
Use switch to select weld amperage range.
NOTICE − Do not use ether. Using ether
voids warranty.
Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
NOTICE − Do not switch under load.
Electric shock can kill.
7
to a complete stop before attempting restart.
10 Polarity Switch (Optional)
!
!
See Section 7-3 for Process/Contactor
switch information.
To Start:
If engine does not start, let engine come
Use switch to select front panel or remote
voltage/amperage control. For remote control, place switch in Remote position and connect remote control to Remote 14 receptacle
RC14 (see Sections 5-13 and 7-4).
Voltage/Amperage Adjust Switch And
Remote 14 Receptacle
Do not use AC output in damp areas,
if movement is confined, or if there is
a danger of falling.
Use Polarity/AC switch to select AC or DC
weld output and DC weld output polarity. For
Direct Current Electrode Negative (DCEN),
turn switch to − (Negative) position. For Direct
Current Electrode Positive (DCEP), turn
switch to + (Positive) position. For weld processes that require alternating current (AC),
use AC position.
Weld Meters
12 AC/DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
13 AC/DC Ammeter (Optional)
Ammeter displays amperage output of the
unit.
14 Battery Voltmeter (Optional)
Use gauge to check battery voltage and monitor engine charging system. The meter
should read about 14 volts DC when the engine is running and about 12 volts DC when
the engine is stopped.
OM-4421 Page 37
7-3. Process/Contactor Switch On CC/CV Models
1
1
Process/Contactor Switch
!
Weld output terminals are energized when Process/Contactor
switch is in an Weld Terminals
Always On position and the engine is running.
!
DC voltage is still present at the
weld terminals when Process/
Contactor switch is in the Remote On/Off Switch Required −
Stick position and the engine is
running.
Use switch to select weld process and
weld output on/off control (see table below and Section 7-4).
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 Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use Stick position for air carbon arc
(CAC-A) cutting and gouging.
When switch is in a Stick position, the
arc drive (dig) circuit provides additional amperage during low voltage (short
arc length conditions) to prevent “sticking” electrodes.
The arc drive (dig) circuit is disabled
when switch is in MIG or TIG positions.
Place switch in Weld Terminals Al-
ways On - Stick position when using optional three-phase generator
(see Section 8-2).
The engine auto idle option does
not work in the Remote On/Off
Switch Required-TIG mode.
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Engine Auto Idle (Optional)
Remote On/Off Switch Required − TIG, HF Required
Or Scratch Start TIG
GTAW With HF Unit, Pulsing
Device, Or Remote Control
At Remote 14 Receptacle
Not Active
Remote On/Off Switch
Required − Stick
Stick (SMAW) With Remote On/Off
At Remote 14 Receptacle
Active
Remote On/Off Switch
Required − CV Feeder
Using Remote
MIG (GMAW)
At Remote 14 Receptacle
Active
Weld Terminals Always On −
Wire
MIG (GMAW)
Electrode Hot
Active
Weld Terminals Always On −
Stick
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting
And Gouging
Electrode Hot
Active
Weld Terminals Always On −
TIG, Scratch Start
TIG Scratch Start (GTAW)
Electrode Hot
Active
OM-4421 Page 38
7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)
1
Remote 14 Receptacle RC14
Connect optional remote control to
RC14 (see Section 5-13).
1
In Example:
Process = Stick (Using Remote On/Off)
Range = 115 to 320 A DC
Min = 115 A DC
Max = 320 A DC
Example: Combination Remote Amperage Control (Stick)
Max (320 A DC)
Min (115 A DC)
Set V/A
Adjust Switch
Set Remote
Process
Set Range
Control Not
Used In Remote
Stick Mode
Adjust Optional Remote Control
In Example:
Process = TIG (Using Remote On/Off)
Range = 35 to 250 A DC
Percentage Of Range = 50%
Min = 35 A DC
Max = About 143 A DC (50% of 35 to 250)
Example: Combination Remote Amperage Control (TIG)
Max (143 A DC)
Min (35 A DC)
Set V/A
Adjust Switch
Set Remote
Process
Set Range
Set Control
Adjust Optional Remote Control
0774 / Ref. 215 158 / Ref. 803 602
OM-4421 Page 39
7-5. Fuel/Hour Gauge Descriptions
OM-4421 Page 40
SECTION 8 − OPERATING AUXILIARY EQUIPMENT
8-1. Domestic Auxilary Power Receptacles
1
120 V 20 A AC GFCI
Receptacle GFCI1
2
240 V 30 A AC Twistlock
Receptacle RC1
Receptacles supply 60 Hz singlephase power at weld/power speed.
1
3
2
If a ground fault is detected, GFCI
Reset button pops out and
receptacle does not work. Check
for faulty tools plugged in
receptacle. Press button to reset
GFCI1.
At least once a month, run en-
gine at weld/power speed and
press test button to verify GFCI
is working properly.
4
3
Supplementary Protector CB1
4
Supplementary Protector CB2
CB1 protects RC1 and the generator winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset.
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset.
If
a supplementary protector
continues to open, contact
Factory Authorized Service
Agent.
Generator
power is not affected by weld output.
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all receptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
191 624-A
OM-4421 Page 41
8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)
Place Process/Contactor switch
1
Single-Phase Power Connection
in Weld Terminals Always On Stick position when using threephase generator (see Section
7-3).
2
Single-Phase Generator Power
1
120/240 V 50 A Receptacle
RC5
RC5 is connected to the optional
three-phase generator and supplies
60 Hz single-phase power at weld/
power speed. Maximum output from
RC5 is 12 kVA/kW. Power available
at RC5 is reduced when welding.
2
Three-Phase Power Connection
!
Volts
Single
Phase
1
120/240
Three
Phase
3
240
Amps
50
36
KVA/KW
12
15
AC
Output
Close panel opening
if no connections are
made to generator.
Frequency
Engine Speed
60 Hz
1850 RPM
Lead 42 connects to GROUND stud on
front of unit.
Jumper 42 is connected to 90 at factory.
93
91
Remove plug
before inserting
leads. Reinstall
bushing.
90
92
4
Rear Of Panel
5
91
92
93
3
6
2
8
Close panel
opening if no
connections
are made to
generator.
Tools Needed:
240V
3-Phase
240V
!
Power and weld outputs are
live at the same time. Disconnect or insulate unused
cables.
Have qualified person install according to circuit diagram and
Generator Power Guidelines
(see Section 12).
Remove generator power panel
mounting screws. Tilt panel forward.
3
Lead 93
4
Lead 92
5
Lead 91
6
Lead 42 (Circuit Grounding
Lead)
7
Lead 90 (Neutral)
8
Isolated Neutral Terminal
9
Jumper Lead 42
12 Supplementary Protector CB7
User Terminals
Connect user-supplied leads to terminals on CB7 and to the isolated
neutral terminal and grounding terminal as necessary.
Supplementary
1-Phase
120V
240V
Stop engine.
11 User-Supplied Leads
240V
120V
!
Lead 42 connects to front panel
Ground stud.
11
9
Three-Phase Generator Power
Jumper 42 is connected to lead 90 at
factory. Jumper 42 may be disconnected from neutral to meet applicable electrical codes.
10
!
Supplementary Protector CB7 protects single-phase receptacle RC5
and the load wires from overload. If
CB7 opens, all generator output
stops and the receptacle does not
work.
10 Grounding Terminal
12
7
Supplementary Protector CB7
protector CB7
protects single-phase receptacle
RC5 and the load wires from
overload. If CB7 opens, all generator output stops and the receptacle does not work.
Reinstall generator power panel.
Ref. 197 399 / 802 332-E / 803 655
OM-4421 Page 42
8-3. Export Auxiliary Power Receptacles
4
3
European Receptacle
Australian Receptacle
1
2
5
South African Receptacle
6
238 127-A / 805 259-A
1
120V 15/20A AC Receptacle GFCI1
tacles is 4 kVA/kW.
Receptacles supply 60 Hz single-phase
power at weld/power speed.
EXAMPLE: If 13 A is drawn from RC1, only
7 A is available at GFCI1:
If a ground fault is detected, GFCI1 Reset
button pops out and receptacle does not
work. Check for faulty tools plugged into receptacle. Press button to reset GFCI1.
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
At least once a month, run engine at
CB2 protects GFCI1 from overload. If a circuit breaker opens, the receptacle does not
work. Press CB2 to reset breaker.
weld/power speed and press test button to verify GFCI is working properly.
Maximum output is 2.4 kVA/kW from GFCI1
and 4 kVa/kW from RC1.
Maximum combined output of all recep-
2
3
Circuit Breaker CB2
Earth Leakage Circuit Breaker
ELCB1
ELCB1 protects RC1 from Earth leakage
fault. If circuit breaker opens the receptacle
does not work. Place circuit breaker switch
in the On position to reset breaker.
At least once a month, press test but4
5
6
ton. If ELCB is working properly, power
will be disconnected. Reset breaker.
220V 16A AC European
Receptacle RC1
240 V 15 A AC Australian
Receptacle RC1
240 V 15 A AC South African
Receptacle RC1
If a circuit breaker continues to open,
contact Factory Authorized Service
Agent.
OM-4421 Page 43
SECTION 9 − MAINTENANCE & TROUBLESHOOTING
9-1. Maintenance Label
OM-4421 Page 44
9-2. Routine Maintenance
!
Recycle engine
fluids.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Every
8
Hours
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
Section 5-9,
9-7
FUEL
WATER
Fuel/Water Separator
Fuel Level
Oil Level
Oil, Fuel Spills
Coolant Level
Every
50
Hours
Weld Terminals
Every
100
Hours
Section 9-4
Battery Terminals
Every
250
Hours
Air Cleaner Hoses
Air Cleaner Element
Engine
Manual,
Section
NO TAG
1/2 in.
(13 mm)
Unreadable Labels
Every
500
Hours
Fan Belt Tension
Spark Arrestor
NOTICE − Change engine
oil and filter after initial 50 to
75 hours of use.
Weld Cables
Every
1000
Hours
Section 9-7
Oil Oil Filter
FUEL
OR
Section 9-7,
9-3 and Engine Manual
SLUDGE
Radiator Fluid Level And
Thermostat
Inside Unit
Slip Rings*
Brushes*
Valve Clearance*
Fuel Filter
Drain Sludge
Every
2000
Hours
Injectors*
OM-4421 Page 45
9-3. Checking Generator Brushes
!
Stop engine and let cool.
1
Generator Brush
Mark and disconnect leads at brush holder cap. Remove brushes.
Replace brushes if damaged or if brush
material is at or near minimum length.
Minimum Length:
5/8 in (16 mm)
New Length: 1-1/4 in (32 mm)
Replace
Damaged Brushes
1
Ref 215 158
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4421 Page 46
9-4. Servicing Air Cleaner
!
1
2
3
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.
4
The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
Optional
5
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
1
Keep nozzle
2 in (51 mm)
from element.
Housing
2
Safety Element (Optional)
3
Primary Element
4
Dust Cap
5
Dust Ejector
To clean air filter:
Blow
Inspect
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
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).
aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 215 158
OM-4421 Page 47
9-5. Inspecting/Cleaning Optional Spark Arrestor
!
Stop engine and let cool.
1
Spark Arrestor Muffler
2
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
2
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
!
Stop engine and let cool.
Reinstall cleanout plug.
1
Tools Needed:
3/8 in
803 656 / Ref. 236 972
OM-4421 Page 48
9-6. Adjusting Engine Speed
Engine Speed
(No Load)
1850 rpm max
(61.6 Hz)
1250 rpm
(41.6 Hz)
1
Engine Speed Adjustment
After tuning engine, check engine speed with tachometer or
frequency meter. See table for
proper no load speed. If necessary, adjust speed as follows:
Start engine and run until warm.
Turn Process/Contactor switch
to Stick − Weld Terminals Always On position.
Standard Model Idle Speed
Adjustment
2
1
Adjustment Screw
2
Lock Nut
Loosen lock nut. Turn screw until
engine runs at idle speed. Tighten nut.
Models With Automatic Idle
Option
3
Throttle Rod / Plunger
4
Lock Nut
5
Rubber Boot
Adjustment screw is not used to
adjust engine speed when automatic idle option is installed.
To
prevent solenoid damage, be sure a 1/8 in (3 mm)
gap exists between the engine low speed screw and
throttle lever when the solenoid is held in the energized
position.
Unhook rubber boot from the solenoid housing but leave connected to plunger.
Loosen lock nut. Place Engine
Control Switch in Auto position.
4
3
Turn throttle rod and plunger until engine runs at idle speed.
Tighten lock nut.
Hook rubber boot back onto solenoid housing.
Be
sure solenoid plunger
pulls all the way in (“bottoms”) when energized.
Weld/Power Speed
Adjustment
Weld/power speed
adjustment must be done by the
engine manufacturer’s factory authorized service
agent.
Tampering with adjustments
other than shown may affect
engine warranty.
5
!
Stop engine.
803 563
OM-4421 Page 49
9-7. Servicing Fuel And Lubrication Systems
4
5
3
7
6
!
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
Fuel Line
5
Primary Fuel Filter (Fuel/
Water Separator)
6
Petcock
7
Secondary Fuel Filter
8
Fuel Tank Sludge Drain Valve
To change oil and filter:
1
Route oil drain hose and valve
through hole in base. See engine
manual and engine maintenance
label for oil/filter change information.
To drain water from fuel system:
Open primary fuel filter petcock and
drain water into metal container.
Close petcock when water-free fuel
flows.
To replace primary fuel filter:
Turn filter counterclockwise. Remove filter.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new filter. Install new filter and turn clockwise. Bleed air from fuel system according to engine manual.
Inspect fuel lines, and replace if
cracked or worn.
To replace secondary fuel filter:
See engine manual.
2
8
To drain sludge from fuel tank:
!
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.
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.
Tools Needed:
803 605-D
OM-4421 Page 50
9-8. Overload Protection
!
Stop engine.
When
a supplementary protector,
circuit breaker or fuse opens, it usually indicates a more serious problem
exists. Contact Factory Authorized
Service Agent.
1
2
2
F1 and F2 protect the stator exciter winding from overload. If F1 opens, weld and
generator power is low or stops entirely.
If F2 opens, weld output is low or stops
entirely. 4 kVA/kW generator power is still
available.
1
3
4
5
9
8
7
Fuse F1
Fuse F2
Circuit Breaker CB4 (Not Shown)
Supplementary Protector CB5
(CC/CV Models Only)
Supplementary Protector CB6
(CC/CV Models Only)
6
Circuit Breaker CB10 (Not Shown)
7
Supplementary Protector CB11
8
Supplementary Protector CB12
9
Supplementary Protector CB13
10 Circuit Breaker CB14 (Not Shown)
CB4 protects the welding arc drive (dig)
circuit. If CB4 opens, electrode may stick
to the workpiece more frequently during
low voltage (short arc length) conditions.
CB4 automatically resets when the fault
is corrected.
4
5
CB5 protects the 24 volt ac output to remote receptacle RC14, and 24 volt output
to field current regulator board PC1 (CC/
CV models only). If CB5 opens, weld output and 24 volt output to RC14 stops. On
units with optional three-phase generator, generator power output at receptacle
RC5 also stops if CB5 opens.
CB6 protects the 115 volt ac output to remote receptacle RC14 (CC/CV models
only). If CB6 opens, 115 volt output to
RC14 stops.
CB10 protects the engine battery circuit.
If CB10 opens, the engine will not crank.
CB10 automatically resets when the fault
is corrected.
CB11 protects the weld control circuit. On
CC models, if CB11 opens the max OCV
circuit does not work and open circuit
voltage is variable at all times (see max
OCV note under Weld Controls in Section
6-2). If CB11 opens on CV models, weld
output stops (generator power is still
available).
CB12 protects the field flashing circuit. If
CB12 opens, the generator may not excite at start-up and weld and generator
power output may not be available.
CB13 protects the engine control circuit.
If CB13 opens, the engine does not
crank.
CB14 protects throttle solenoid TS1 on
units with auto idle option. If CB14 opens,
the engine does not run at idle speed.
CB14 automatically resets when the fault
is corrected.
Press button to reset supplementary protector.
803 605
OM-4421 Page 51
9-9. Troubleshooting
A. Welding − CC Models
Trouble
Remedy
No weld output; generator power output Check position of Ampere Range switch.
okay at ac receptacles.
Check position of optional Polarity switch.
Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
control to Remote Amperage Adjust receptacle RC13 (see Sections 5-12 and 6-1).
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-12).
Check fuse F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check integrated rectifier SR2 and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and weld excitation circuit.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1 (see Section 9-8).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output.
Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Have Factory Authorized Service Agent check brushes and slip rings.
High weld output.
Check position of Ampere Range switch and Voltage/Amperage Adjust control.
Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if necessary. See Section 9-6 for idle speed adjustment.
Have Factory Authorized Service Agent check OCV control circuit.
Low weld output.
Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if necessary. See Section 9-6 for idle speed adjustment.
Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8).
frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.
length) conditions.
Low open-circuit voltage.
Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if necessary. See Section 9-6 for idle speed adjustment.
Place Stick/TIG switch in Stick position.
Maximum weld output only in each Have Factory Authorized Service Agent check control relay CR7.
ampere range (with Stick/TIG Selection
switch in Stick position).
No remote fine amperage control.
Place Amperage Adjust switch in Remote position.
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-12).
Reset supplementary protector CB11 (see Section 9-8). Have Factory Authorized Service Agent check
control relay CR7.
OM-4421 Page 52
Trouble
No remote fine amperage control.
Remedy
Repair or replace remote control device.
Have Factory Authorized Service Agent check OCV control circuit.
B. Welding − CC/CV Models
Trouble
Remedy
No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at ac receptacles.
On/Off Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14
(see Sections 5-13 and 7-1).
Check position of Ampere Range switch.
Check position of optional Polarity switch or Polarity/AC switch.
Reset supplementary protector CB11 (see Section 9-8).
Reset supplementary protector CB5 (see Section 9-8). Check for faulty remote device connected to
RC14.
Check and secure connections to Remote 14 receptacle RC14 (see Section 5-13).
Have Factory Authorized Service Agent check connector board PC6 and connections.
Check fuse F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check
brushes and slip rings, weld excitation circuit, field current regulator board PC1, and the rotor.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output.
Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Have Factory Authorized Service Agent check brushes and slip rings.
High weld output.
Check position of Ampere Range switch and Voltage/Amperage Adjust control.
Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if necessary. See Section 9-6 for idle speed adjustment.
Have Factory Authorized Service Agent check field current regulator board PC1, and PC1 voltage feedback circuit.
Voltage/Amperage control does not Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere
work when welding in Stick mode.
Range switch in highest range.
Low weld output.
Check position of Ampere Range switch and Voltage/Amperage Adjust control.
Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if necessary. See Section 9-6 for idle speed adjustment.
Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8).
frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.
length) conditions.
Low open-circuit voltage.
Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if necessary. See Section 9-6 for idle speed adjustment.
Check position of Process/Contactor switch.
No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position.
control.
Check and secure connections to Remote 14 receptacle RC14 (see Section 5-13).
OM-4421 Page 53
Trouble
Remedy
No remote fine amperage or voltage Repair or replace remote control device.
control.
Have Factory Authorized Service Agent check PC1 sensing leads (36 and 37), and connections.
Constant speed wire feeder does not Reset supplementary protector CB5 or CB6 (see Section 9-8).
work.
Check and secure connections to Remote 14 receptacle RC14 (see Section 5-13).
Repair or replace wire feeder.
Low CV weld output.
Set Ampere Range switch to highest range.
Increase Voltage/Amperage Adjust Control setting.
Min or max CV weld output only.
Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.
Repair or replace remote control device.
Have Factory Authorized Service Agent check Amperage/Voltage Adjust Control R1, and field current
regulator board PC1.
C. Standard Generator Power
Trouble
Remedy
No generator power output at ac recep- Reset receptacle supplementary protectors.
tacles; weld output okay.
Reset GFCI receptacle.
No generator power or weld output.
Disconnect equipment from generator power receptacles during start-up.
Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, diode/capacitor board D1/C1, and the rotor.
Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1 .
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power ac re- Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if necesceptacles.
sary. See Section 9-6 for idle speed adjustment.
Have Factory Authorized Service Agent adjust generator power field current resistor R3.
Low output at generator power ac recep- Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if necestacles.
sary. See Section 9-6 for idle speed adjustment.
Check fuse F1, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check integrated rectifier SR1, resistor R3, and capacitor C9.
D. Optional Three-Phase Generator Power (CC/CV Models Only)
Trouble
No or low output at optional threephase generator/receptacle RC5.
Remedy
Place Process/Contactor switch in Weld Terminals Always On - Stick position (see Section 7-3).
Reset supplementary protector CB7(see Section 8-2).
Reset supplementary protector CB5 (see Section 9-8).
Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if necessary. See Section 9-6 for idle speed adjustment.
Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
PC1.
High output at optional three-phase
generator/receptacle RC5.
Check engine speed, and have engine manufacturer’s factory authorized service agent adjust if necessary. See Section 9-6 for idle speed adjustment.
Have Factory Authorized Service Agent check field current regulator board PC1, and PC1 voltage
feedback circuit.
Erratic output at optional three-phase Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
generator/receptacle RC5.
PC1.
OM-4421 Page 54
E. Engine
Trouble
Engine will not crank.
Remedy
Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-8).
Have Factory Authorized Service Agent check engine wiring harness and components.
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check control relay CR1 and Engine Control switch S1.
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 engine wiring harness, fuel gauge/hourmeter, control
relay CR5, fuel pump, fuel solenoid FS1, and diode/capacitor board D10/C10.
Air in fuel system. See engine manual.
Engine starts, but stops when Engine Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
Control switch is released.
temperature is too high (see Section 5-9). Automatic shutdown system is inhibited for 30 seconds after
start-up.
Have Factory Authorized Service Agent check fuel gauge/hourmeter, and control relay CR5.
Engine hard to start in cold weather.
Use starting aid switch (see Section 6-1 or 7-1).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 9-1).
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 5-9). Automatic shutdown system is inhibited for 30 seconds after
start-up.
See engine manual.
Engine slowly stopped and cannot be
restarted.
Check fuel level.
Check engine air and fuel filters (see Sections 9-4 and 9-7).
See engine manual.
Battery discharges between uses.
Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine idles, but does not come up to
weld speed (models with idle option
only).
Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1.
Check for obstructed throttle solenoid.
Engine does not run at idle speed
(models with idle option only).
CC models: place Stick/TIG Selection switch in Stick position.
CC/CV models: place Process/Contactor switch in any position but Remote On/Off Switch RequiredTIG.
Check for obstructed throttle solenoid.
Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.
Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 11).
wetstacking occurs.
OM-4421 Page 55
SECTION 10 − ELECTRICAL DIAGRAMS
Figure 10-1. Circuit Diagram For CC Welding Generator
OM-4421 Page 56
240 152-A
OM-4421 Page 57
Figure 10-2. Circuit Diagram For CC/CV Welding Generator
OM-4421 Page 58
240 153-A
OM-4421 Page 59
SECTION 11 − RUN-IN PROCEDURE
run_in1 2007−04
11-1. 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-4421 Page 60
11-2. Run-In Procedure Using Load Bank
Stop engine.
Do not touch hot exhaust pipe,
engine parts, or load bank/grid.
Keep exhaust and pipe away
from flammables.
4
2
1
NOTICE − Do not perform runin 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-4421 Page 61
11-3. Run-In Procedure Using Resistance Grid
Stop engine.
Do not touch hot exhaust pipe,
engine parts, or load bank/grid.
Keep exhaust and pipe away
from flammables.
6
NOTICE − Do not perform runin procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
2
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-4421 Page 62
SECTION 12 − 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.
12-1. Selecting Equipment
1
2
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
Be sure equipment has double
insulated symbol and/or wording on it.
1
!
2
Do not use 2-prong plug unless equipment is double insulated.
3
OR
gen_pwr 2008−01 − ST-800 577
12-2. Grounding Generator To Truck Or Trailer Frame
!
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.
1
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
2
3
1
2
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
Electrically
bond generator
frame to vehicle frame by metal-to-metal contact.
GND/PE
!
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.
!
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
3
800 652-D
OM-4421 Page 63
12-3. Grounding When Supplying Building Systems
1
2
1
2
Use #10 AWG or larger insulated
copper wire.
3
GND/PE
Equipment Grounding
Terminal
Grounding Cable
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
12-4. 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 12-8).
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-4421 Page 64
12-5. 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
12-6. 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-4421 Page 65
12-7. 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-4421 Page 66
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
12-8. 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
12-9. 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-4421 Page 67
12-10. 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 and ground
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.
1 Utility Electrical Service
5
2 Transfer Switch (Double-Throw)
Essential
Loads
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 12-4).
OM-4421 Page 68
12-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
6
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-4421 Page 69
SECTION 13 − PARTS LIST
128
129
24
23
22
6
7
19
8
21
25
27
5
4
2
20
18
9
3
10
11
12
1
26
13
17
14
15
16
28
29
31
30
118 (CV)
119 (CV)
112
117 (Fig. 13−8)
120
127
32
111
113
121
122
115
123
116 (CC ONLY)
124
Figure 13-1. Main Assembly (Export Model Shown)
OM-4421 Page 70
109
108
107
126
125 (Fig. 13−4 OR 13−5)
110
106
39
35
40
38
37
34
54
53
52
36
33
51
55
50
41
48
47
42
128
56
57
49
43 45
44
58
59
46
61
93 (Fig. 13−7)
95
105
104
94
68
69
70
71
72
96
97
98
99
92
90
100
101
102
103
91
62
63
64
65
66
67
75
60
76
77
78
79
73
74
89
80
81
82
86
87
83
84
88
85
803 646-J
OM-4421 Page 71
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 189 824
. . . 1 . . . . . . . . . . . . ♦199 294
. . . 2 . . . . . . . . . . . . . 191 626
. . . 3 . . . . . . . . . . . . . 189 975
. . . 4 . . . . . . . . . . . . +200 989
. . . 4 . . . . . . . . . . . ♦+210 736
. . . 5 . . . . . . . . . . . . . 199 592
. . . 6 . . . . . . . . . . . . . 190 076
. . . 6 . . . . . . . . . . . . ♦202 635
. . . 7 . . . . . . . . . . . . . 190 992
. . . 8 . . . . . . . . . . . . . . 220539
. . . 9 . . . . . . . . . . . . . 208 141
. . . 10 . . . . . . . . . . . . . 189 826
. . . 10 . . . . . . . . . . . . ♦199 298
. . . 11 . . . . . Z1 . . . CC214 972
. . . 11 . . . . . Z1 . . . CV214 964
. . . 12 . . . . . . . . . . . . . 206 352
. . . 13 . . . . . 1T . . . . 038 621
. . . . . . . . . . . . . . . . . . . 038 620
. . . 14 . . . . . . . . . . . . . 081 499
. . . 15 . . SR4, SR5 . 035 704
. . . 16 . . . . CB4 . . . 045 061
. . . 17 . . . . . T1 . . . . 201 613
. . . 17 . . . . . T1 . . . ♦205 636
. . . 18 . . . . . . . . . . . . . 173 352
. . . 19 . . . . . . . . . . . . . 189 708
. . . 20 . . . . . . . . . . . . . 191 307
. . . 21 . . . . . . . . . . . . . 189 763
. . . 22 . . . . . . . . . . . . . 189 618
. . . 23 . . . . . . . . . . . . . 198 457
. . . 24 . . . . . . . . . . . . . 173 036
. . . . . . . . . . . . . . . . . . . 010 863
. . . 25 . . . . . . . . . . . . . 189 764
. . . . . . . . . . . . . . . . . . . *192 938
. . . . . . . . . . . . . . . . . *♦192 939
. . . 26 . . . . . . . . . . . . . 189 464
. . . . . . . . . . . . . . . . . . . 173 909
. . . 27 . . . . . . . . . . . . . 191 819
. . . . . . . . . . . . . . . . . . . 198 584
. . . 28 . . . . . . . . . . . . . 095 636
. . . 29 . . . . . . . . . . . . . 206 297
. . . . . . . . . . . . . . . . . . . 192 741
. . . 30 . . . . . . . . . . . . . *192 744
. . . 31 . . . . . . . . . . . . . 201 658
. . . 32 . . . . . . . . . . . . . 201 697
. . . . . . . . . . . . . . . . . . . 203 260
. . . 33 . . . . . . . . . . . . +201 934
. . . 33 . . . . . . . . . . . ♦+202 640
. . . 34 . . . . . . . . . . . . . 189 052
. . . 35 . . . . . . . . . . . . . 190 198
. . . 36 . . . . . . . . . . . . . 192 041
. . . 37 . . . . . . . . . . . . . 222 513
. . . 38 . . . . . . . . . . . . . 224 265
. . . 39 . . . . . . . . . . . . . 105 734
. . . 40 . . . . . . . . . . . . . 201 851
OM-4421 Page 72
. . PANEL, gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, gen LH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUMPER, door engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DOOR, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DOOR, engine access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LATCH, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CHANNEL, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CHANNEL, stiffener engine access e−coat . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KEEPER, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, diesel engine maintenance (required on rh door only) . . . . . . . . .
. . STOP, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, rocker ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACE, front to center upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 30A 4 pole frict term str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, integ bridge 40. amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT BREAKER, auto reset 24vdc 7 amp . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER w/bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER w/bracket (environmental coating) . . . . . . . . . . . . . . . . .
. . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . .
. . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBE, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, elbow air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CLAMP, hose 1.125 − 3.000 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, sae .312 id x .560 od x 24.000 (order by ft) . . . . . . . . . . . . . . . . . .
. . HOSE, sae .312 id x .560 od x 14.000 (order by ft) . . . . . . . . . . . . . . . . . .
. . HOSE, sae .312 id x .560 od x 5.000 (order by ft) . . . . . . . . . . . . . . . . . . . .
. . HOSE, sae .187 id x .41 od x 30.000 (order by ft) . . . . . . . . . . . . . . . . . . .
. . BASE, fuel filter w/fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BLOCK, spacer mtg filter base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FILTER, fuel spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . UPRIGHT, center assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PAN, reactor and rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LABEL, caution do not use ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, plastic neck filler fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAP, tank screw−on 3.500 in w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning falling equipment can cause serious . . . . . . . . . . . . . . . . .
. . LABEL, warning hot exhaust parts do not touch . . . . . . . . . . . . . . . . . . . . .
. . PIPE, muffler extension elbow 1.750 od . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, radiator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly (Continued)
. . . 40 . . . . . . . . . . . . ♦202 629 . . COVER, radiator access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . . 191 354 . . SUPPORT, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . ♦202 633 . . SUPPORT, cover e−coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . . . . . . . . 010 875 . . CLAMP, muffler 2.000 dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . . . 203 180 . . MANIFOLD, exhaust muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 203 179 . . . . BRACKET, support muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . . . 195 012 . . SPARK ARRESTOR KIT (Horizontal) (export models only) . . . . . . . . . .
. . . 44 . . . . . . . . . . . . . 237 010 . . ENGINE, Perkins dsl elec 404D−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *214 931 . . . . SENDER, Coolant Temp & 110c N.o. Switch . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *215 094 . . . . SWITCH, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 023 562 . . . . CLAMP, hose .312 − .875 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *197 899 . . . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *192 744 . . . . FILTER, fuel spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *197 997 . . . . FILTER, fuel secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 45 . . . . . . . . . . . . . 214 658 . . HOSE, radiator upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . . . . *197 944 . . BELT, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 47 . . . . . . . . . . . . . 217 775 . . GUARD, belt (export models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 47 . . . . . . . . . . . . . 202 017 . . GUARD, belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 48 . . . . . . . . . . . . . 220 280 . . RADIATOR, w/shroud (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 220 281 . . . . SHROUD, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 214 884 . . . . RADIATOR, w/14# cap 4 row core 3 pass . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 187 120 . . . . CAP, radiator pressure 14 lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 49 . . . . . . . . . . . . . 225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . . 201 749 . . UPRIGHT, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . ♦207 188 . . UPRIGHT, rear ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . ♦207 005 . . GRILL, rear panel ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 51 . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . .
. . . 52 . . . . . . . . . . . . . 190 206 . . CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng . . . . . . . . . . . . .
. . . 53 . . . . . . . . . . . . . 190 207 . . CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng . . . . . . . . . . . . .
. . . 54 . . . . . . . . . . . . . 203 430 . . BRACKET, battery holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 55 . . . . . . . . . . . . . 190 897 . . BATTERY, stor 12V 650crk 110rsv gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 56 . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 57 . . . . . . . . . . . . +225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . .
. . . 58 . . . . . . . . . . . . +201 183 . . COVER, battery access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 58 . . . . . . . . . . . ♦+202 639 . . COVER, battery access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 59 . . . . . . . . . . . . . 201 006 . . BOLT, j stl .312−18 x 8.500 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 60 . . . . . . . . . . . . +215 006 . . GUARD, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 61 . . . . . . . . . . . . . 197 496 . . HOSE, radiator lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 199 505 . . HOSE, oil drain assy 32 in (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 62 . . . . . . . . . . . . . 165 271 . . . . VALVE, oil drain 3/8−18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 63 . . . . . . . . . . . . . 176 529 . . . . FITTING, hose brs barbed fem 1/2tbg x 3/8NPT . . . . . . . . . . . . . . . . . . .
. . . 64 . . . . . . . . . . . . . . 113 854 . . . . HOSE, SAE .500 ID x .780 OD xc oil (order by ft) . . . . . . . . . . . . . . . . . .
. . . 65 . . . . . . . . . . . . . 197 448 . . FITTING, hose brs barbed elbow m 1/2 tbg x 3/8 npt . . . . . . . . . . . . . . . . .
. . . 66 . . . . . . . . . . . . . . . . . . . . . . . . WASHER, oil drain (available through engine manufacturer) . . . . . . . . . . .
. . . 67 . . . . . . . . . . . . . 197 196 . . FITTING, adapter oil drain 12mm male x 3/8 npt female . . . . . . . . . . . . . .
. . . 68 . . . . . . . . . . . . . 199 849 . . SCREW, 625−11 x 4.00hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 69 . . . . . . . . . . . . . 071 731 . . WASHER, flat .656 ID x 2.250 OD x .187T stl pld . . . . . . . . . . . . . . . . . . . .
. . . 70 . . . . . . . . . . . . . 197 488 . . BRACKET, mtg LH Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 70 . . . . . . . . . . . . . 236 752 . . BRACKET, mtg RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 71 . . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 72 . . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 73 . . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 . . . . . . . . . . . . . . . . . .
. . . 74 . . . . . . . . . . . . . 135 205 . . NUT, 625−11 .94hex .76H stl pld elastic stop nut . . . . . . . . . . . . . . . . . . . . .
. . . 75 . . . . . . . . . . . . . 190 992 . . KEEPER, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 76 . . . . . . . . . . . . . 190 076 . . CHANNEL, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 76 . . . . . . . . . . . . ♦202 635 . . CHANNEL, stiffener engine access e−coat . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-4421 Page 73
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly (Continued)
. . . 77 . . . . . . . . . . . . . 191 626 . . BUMPER, door engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 78 . . . . . . . . . . . . . 199 592 . . LATCH, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 79 . . . . . . . . . . . . . 220 539 . . LABEL, diesel engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 80 . . . . . . . . . . . . +200 989 . . DOOR, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 81 . . . . . . . . . . . ♦+210 736 . . DOOR, engine access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 81 . . . . . . . . . . . . . . . . . . . . . . . . Not Applicable for Perkins powered machines
. . . 82 . . . . . . . . . . . . . 189 975 . . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . ♦+199 301 . . PANEL, engine side ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 83 . . . . . . . . . . . . . 190 190 . . TANK, coolant recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 84 . . . . . . . . . . . . . 189 826 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 85 . . . . . . . . . . . . ♦199 298 . . PANEL, rocker ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 85 . . . . . . . . . . . . . 208 141 . . STOP, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 86 . . . . . . . . . . . . . 189 827 . . PANEL, gen RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 87 . . . . . . . . . . . . ♦199 300 . . PANEL, gen RH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 87 . . . . . . . . . . . . . *197 997 . . FILTER, fuel secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 88 . . . . . . . . . . . . . 173 909 . . HOSE, sae .312 id x .560 od (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 89 . . . . . . . . . . . . . . . . . . . . . . . . PUMP, fuel (available through engine manufacturer) . . . . . . . . . . . . . . . . .
. . . 90 . . . . . . . . . . . . . 218 222 . . BRACKET, mtg fuel filter/pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 91 . . . . . . . . . . . . ♦230 636 . . IDLE SOLENOID ASSEMBLY (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 230 634 . . . . SOLENOID, throttle w/4−8.4 lb spring . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 230 829 . . . . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 198 018 . . . . LINKAGE, throttle solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 230 830 . . . . ARM, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 198 109 . . . . SCREW, shld stl sch .250−20 x .437 x .500 shld . . . . . . . . . . . . . . . . .
. . . 92 . . . . . . . . . . . . . 225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . .
. . . 93 . . . . . . . . . . . Figure13-6 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 94 . . . . . . . . . . . . . 218 087 . . TANK, fuel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 95 . . . . . . . . . . . . . 189 909 . . . . FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc . . . . . . . . . . . . . . .
. . . 96 . . . . . . . . . . . . . 095 636 . . . . HOSE, sae .187 id x .410 od x 30.000 (order by ft) . . . . . . . . . . . . . . . . .
. . . 97 . . . . . . . . . . . . . 201 025 . . . . CAP, fuel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 98 . . . . . . . . . . . . . 189 913 . . . . FITTING, stl barbed elbow zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 99 . . . . . . . . . . . . . 190 142 . . . . SENDER, fuel gauge 9.7500 deep tank . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 100 . . . . . . . . . . . . 189 910 . . . . FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc . . . . . . . . . . . . .
. . 101 . . . . . . . . . . . . 181 572 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 102 . . . . . . . . . . . . 189 908 . . . . VALVE, drain fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 103 . . . . . . . . . . . . 191 446 . . . . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . .
. . 104 . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 084 173 . . . . CLAMP, hose .460 − .545clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 105 . . . . . . . . . . . . 189 912 . . . . FITTING, stl barbed elbow w/.047 in orf zinc pld . . . . . . . . . . . . . . . . . . .
. . 106 . . . . . . . . . . . . 224 266 . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 107 . . . . . . . . . . . . 191 897 . . BRACKET, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 108 . . . . . . . . . . . . 192 362 . . BRACKET, mtg nyl 1/2 conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 109 . . . . . . . . . . . . 196 220 . . BRACKET, hold down fuel tank rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 110 . . . . . . . . . . . +200 999 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 110 . . . . . . . . . . ♦+203 382 . . BASE e−coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 111 . . . . . . . . . . . . 218 086 . . BRACKET, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 112 . . . . . . . . . . . . 173 352 . . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . .
. . 113 . . . . . . . . . . . . 189 731 . . FIREWALL, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 114 . . . . . Figures 13-2, 13-3 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 115 . . . . R3 . . . . 189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . .
. . 116 . . . . R2 . . . CC189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . .
. . 117 . . . . . . . . . Figure 13-7 . . MAIN RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 118 . . . PC1 . . CV189 143 . . MODULE, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 119 . . . . . . . . . . . CV193 453 . . BRACKET, mtg box fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 120 . . . . . . . . . . . . 191 448 . . TOP, cover front upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4421 Page 74
4
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1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
6ft
4
2
1
2
4
1
1
1
1
1
3ft
1
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly (Continued)
. . 120 . . . . . . . . . . . ♦199 305 . . TOP, cover front upright ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 121 . . . . . . . . . . . . 212 944 . . LABEL, cc stick overlap weld ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 122 . . . . . . . . . . . . . . . . . . . . . . . Not Applicable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 123 . . . . . . . . . . . +201 750 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 123 . . . . . . . . . . ♦+202 637 . . UPRIGHT, front ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 223 103 . . LABEL, ce sound power level 97db (CC export models only) . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 173 216 . . LABEL, ce european community mark (CC export models only) . . . . . . 1
. . 124 . . . . . . . . . . . . 233 953 . . LABEL, warning general precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 125 . . . . . Figures 13-4, 13-5 PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 126 . . . CT1 . . ♦202 130 . . XFMR, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 127 . . . . . . . . . . . +189 828 . . PANEL, engine side (400P Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 127 . . . . . . . . . . ♦+199 301 . . PANEL, engine side ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 128 . . . . . . . . . . . . 233 088 . . LABEL, danger using a generator indoors can kill you in minutes (unit) . 1
. . . . . . . . . . . . . . . . . . . 190 058 . . NUT, .250−20 u−nut multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . 049 525 . . NUT, 312−18 u−nut multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . 238 650 . . LABEL, hour/fuel meter usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 215 052 . . KIT, label (includes safety & informational labels) CC models . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 215 212 . . KIT, label (includes safety & informational labels) CC/CV models . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 216 989 . . KIT, label (includes safety & informational labels) (CC export models) . 1
. . . . . . . . . . . . . . . . . . . 216 988 . . KIT, label (includes safety & informational labels) (CC/CV export models)1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
C
C CC models only.
C
V CC/CV models only.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement
Parts. Model and serial number required when ordering parts from your local distributor.
OM-4421 Page 75
Hardware is common and
not available unless listed.
6
7
8
9
5
10
4
11
3
2
13
12
1
15
16
14
17
23
22
18
20
21
19
803 647-G
Figure 13-2. Control Box Assembly − CC Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 114)
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
. . . F1, F2 . . *085 874
. . . . . . . . . . . . . 046 432
. . . . CR7 . . . 188 636
. . . . . . . . . . . . . 201 077
. . . . C12 . . . 191 944
. . . . . R6 . . . . 141 424
. . . . . . . . . . . . . 201 078
. . . . . CR3 . . . 090 104
. . . . CR8 . . . 197 325
. . . . CR1 . . . 090 104
. . . . CR6 . . ♦090104
D10/C10, D11/C11, D12 189 701
. . . . CB14 . . ♦230 635
. . . . CB10 . . . 190 374
. . . . CR5 . . . 223 710
. . . . PC7 . . ♦195 706
. . SR1, SR2 . 035 704
. . . . CR4 . . ♦113 247
OM-4421 Page 76
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FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, OCV control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, polyp met film 10. uf 250 vac 10% . . . . . . . . . . . . . . . . . . . .
RESISTOR, ww fxd 30 w 25 ohm faston te . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . .
RELAY, encl 12vdc spst 70a 4pin flange mtg . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . .
RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . .
DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, auto reset 12vdc 8 amp . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, Encl 12vdc Dpst−no 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . .
MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . .
2
2
1
1
1
1
1
1
1
1
1
3
1
1
1
1
2
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-2. Control Box Assembly − CC Models Continued
. . . 19 . . . . . . . . . . . . . 201 079
. . . 20 . . . . . C9 . . . . . 087 110
. . . 21 . . . . . . . . . . . . . 177 136
. . . 22 . . . D1/C1 . . 189 701
. . . 23 CB11, 12, 13 139 266
♦Optional
..
..
..
..
..
COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac . . . . . . . .
1
1
1
1
3
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4421 Page 77
Hardware is common and
not available unless listed.
4
5
6
7
3
8
10
2
9
11
1
12
13
15
16
22
18
21
14
17
19
20
803 648-G
Figure 13-3. Control Box Assembly − CC/CV Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 114)
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8
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12
13
14
15
16
17
18
19
20
. . . F1, F2 . . *085 874
. . . . . . . . . . . . . 046 432
. . . . . . . . . . . . . 201 077
. . . . . . . . . . . . . 201 078
. . . . CR3 . . ♦090 104
. . . . CR8 . . . 197 325
. . . . CR1 . . . 090 104
. . . . CR6 . . ♦090 104
D10/C10, D11/C11, D12 189 701
. . . . CB14 . . ♦230 635
. . . . CB10 . . . 190 374
. . . . CR5 . . . 223 710
. . . . . . . . . . . . . 201 079
. . . . PC7 . . ♦195 706
. . . . SR1 . . . 035 704
. . . . CR4 . . ♦113 247
. . . . PC9 . . . 192 224
. . . . . . . . . . . . . 134 201
. . . . . . . . . . . . . 177 136
. . . . . C9 . . . . . 087 110
OM-4421 Page 78
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FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . .
RELAY, encl 12vdc spst 70a 4pin flange mtg . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . .
RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . .
DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, auto reset 12vdc 8 amp . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 12VDC dpst−no 25A 6pin flange . . . . . . . . . . . . . . . . . . . . . . .
COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND-OFF, support pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
3
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-3. Control Box Assembly − CC/CV Models (Continued)
. . . 21 . . . D1/C1 . . 189 701 . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 CB11, 12, 13 139 266 . . SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac . . . . . . . . 3
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4421 Page 79
Hardware is common and
not available unless listed.
4
3
5
2
1
6
7
8
9
11
10
41
40
39
38
12
13
14
34
37
16
31
21
36
35
15
33
32
17
30
20
18
19
23
22
24
29
28
26
25
27
803 649-D
Figure 13-4. Panel, Front w/Components − CC Models
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-4421 Page 80
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 125)
. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . PLATE SCREENED, ident control rating (order by model and serial number)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (when ordering this item, the nameplate should also be ordered) . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, screened (order by model and serial number) . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 238 616 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . 208 278 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . 188 635 . . RHEOSTAT, WW 300W 34 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 7 . . . . . S6 . . . . . 011 622 . . SWITCH, tgl DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr . . . . . . . . . . . 1
. . . 9 . . . . RC13 . . . 032 897 . . RECEPTACLE, twlk grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S1 . . . . 217 680 . . SWITCH, ignition 4 position w/out handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 207 073 . . LEVER, ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 244 . . WASHER, tooth.728idx1.166odx.050t stl pld int.688 . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S2 . . . . 021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . Figure 13-6 . . AUXILIARY POWER GROUP , Export
. . . . . . . . . . . . . . . . . . . 215 437 . . AUXILIARY POWER GROUP, Domestic (Includes)
. . . . . . . . . . . . . . . . . . . 201 553 . . . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CB1 . . . 201 083 . . . . SUPPLEMENTARY PROTECTOR, man reset 2p 20a 250vac . . . . . . 1
. . . 13 . . . . CB2 . . . 093 996 . . . . SUPPLEMENTARY PRO, man reset 1p 20a 250vac frict . . . . . . . . . . . 1
. . . 14 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . 1
. . . 15 . . . . RC1 . . . 147 632 . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 190 861 . . . . LABEL, warning electric shock and moving parts etc . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . +215 347 . . . . PANEL, gen pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . ♦+215 405 . . . . PANEL, gen pwr ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 083 030 . . . . STUD, brs .250−20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 601 836 . . . . NUT, 250−20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 20 . . . . . . . . . . . . . 209 056 . . . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . . . . 206 795 . . . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . S12 . . ♦220 491 . . SWITCH, polarity/ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . ♦199 303 . . PANEL, mtg terminal pwr output ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 241 433 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 241 432 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 32 . . . . . . . . . . . . . 201 045 . . COVER, receptacle twistlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . ♦193 228 . . METER, Volt Dc 8− 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . FUEL/HM . . 232 112 . . GAUGE, fuel elec/hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . 217 084 . . GAUGE, Coolant Temp 0− 300 Deg F Electric . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 197 798 . . SENDER, Coolant Temp 300 Deg F M16 X 1.5 . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 217 083 . . GAUGE, Pressure Oil 0−100 Psi Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 193 230 . . SENDER, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . ♦164 873 . . VOLT METER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . ♦164 874 . . AMMETER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . 019 602 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 024 103 . . BLANK, snap−in nyl .750 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
OM-4421 Page 81
Hardware is common and
not available unless listed.
4
3
5
6
2
1
7
8
9
10
11
12
57
56
13
14
55
15
54
16
17
18
53
52
51
50
19
33
48
49 47
46
31
45
20
21
22
30
23
24
32
26
43
44
29
25
28
27
34
35
42
36
41
40
39
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37
803 650-E
Figure 13-5. Panel, Front w/Components − CC/CV Models
OM-4421 Page 82
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 125)
. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . PLATE SCREENED, ident control (order by model and serial number)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (when ordering this item, the nameplate should also be ordered) . . . . . . .
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, screened (order by model and serial number) . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 238 616 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . S3 . . . . 208 278 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . R1 . . . . . 193 118 . . POT, cp flat 1t 2w 1k ohm linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . S6 . . . . 193 234 . . SWITCH, rotary 6 position gold contacts . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 197527 . . Guard, Circuit Breaker (For S6 - Not Included w/Harness) . . . . . . . . . . . .
. . . 7 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . PC6 . . . 192 995 . . CIRCUIT CARD ASSY, connector/receptacle . . . . . . . . . . . . . . . . . . . . . . .
. 10, 11 CB5, CB6 . 093 995 . . SUPPLEMENTARY PRO, man reset 1p 15a 250vac frict . . . . . . . . . . . . .
. . . 12 . . . . . S2 . . . . 021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . S1 . . . . 217 680 . . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 207 073 . . LEVER, ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 201 244 . . WASHER, tooth.728idx1.166odx.050t stl pld int.688 . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . Figure 13-6 . . AUXILIARY POWER GROUP , Export
. . . . . . . . . . . . . . . . . . . 215 437 . . AUXILIARY POWER GROUP, Domestic (Includes)
. . . 14 . . . . CB1 . . . 201 083 . . . . SUPPLEMENTARY PROTECTOR, man reset 2p 20a 250vac . . . . . .
. . . . . . . . . . . . . . . . . . . 201 553 . . . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . CB2 . . . 093 996 . . . . SUPPLEMENTARY PRO, man reset 1p 20a 250vac frict . . . . . . . . . . .
. . . 16 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . .
. . . 17 . . . . RC1 . . . 147 632 . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . .
. . . 18 . . . . RC5 . . ♦182 954 . . . . RCPT, str 3P4W 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . ♦025 248 . . . . STAND-OFF, insul .250-20 x 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . ♦604 102 . . . . CONNECTOR, clamp cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . ♦197 527 . . . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . ♦197 363 . . . . TERMINAL, ring tng screw clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . CB7 . . ♦214 926 . . . . SUPPLEMENTARY PROTECTOR, man reset 3p 50a 250vac . . . . . .
. . . 24 . . . . . . . . . . . . +215 347 . . . . PANEL, generator power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . ♦215 406 . . . . PANEL, generator power ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . +♦215 363 . . . . PANEL, generator power (full kVA option) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . ♦214 927 . . . . BOOT, circuit breaker 1 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . ♦197 508 . . . . PLUG, protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . ♦077 440 . . . . BUSHING, conduit 1 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . 601 836 . . . . NUT, 250−20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . 209 056 . . . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . 083 030 . . . . STUD, brs .250−20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . CT2 . . ♦197 433 . . . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . 190 861 . . . . LABEL, warning electric shock and moving parts etc . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . ♦197 399 . . . . LABEL, warning 3 ph generator power . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . 209 056 . . . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . 206 795 . . . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S12 . . ♦220 491 . . SWITCH, polarity/AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . 199 303 . . PANEL, mtg terminal pwr output ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . PC4, PC5 . 189 744 . . CIRCUIT CARD ASSEMBLY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . 241 433 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
3
1
1
1
1
1
2
1
1
1
1
1
2
1
2
OM-4421 Page 83
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)
. . . 38 . . . . . . . . . . . . . 134 201
. . . 39 . . . . . . . . . . . . . 181 169
. . . 40 . . . . . . . . . . . . . 186 621
. . . 41 . . . . . . . . . . . . ♦059 773
. . . 42 . . . . . . . . . . . . ♦010 647
. . . 43 . . . . . . . . . . . . . 241 432
. . . 44 . . . . . . . . . . . . ♦196 073
. . . 45 . . . . . . . . . . . . . 021 385
. . . 46 . . . . . . . . . . . . . 190 323
. . . 47 . . . . . . . . . . . . . 170 391
. . . 48 . . FUEL/HM . . 232 112
. . . 49 . . . . . . . . . . . . ♦193 228
. . . 50 . . . . . . . . . . . . ♦217 084
. . . . . . . . . . . . . . . . . . . 197 798
. . . 51 . . . . . . . . . . . . . 217 083
. . . . . . . . . . . . . . . . . . . 193 230
. . . 52 . . . . . . . . . . . . ♦164 873
. . . 53 . . . . . . . . . . . . ♦164 874
. . . 54 . . . . . . . . . . . . . 097 922
. . . 55 . . . . . . . . . . . . . 189 161
. . . 56 . . . . . . . . . . . . . 010 647
. . . 57 . . . . . . . . . . . . . 097 924
. . . . . . . . . . . . . . . . . . . 024 103
. . . . . . . . . . . . . . . . . . . 120 304
♦Optional
+
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONN, circ ms protective cap size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GAUGE, fuel elec/hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METER, Volt Dc 8− 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . .
GAUGE, Coolant Temp 0− 300 Deg F Electric . . . . . . . . . . . . . . . . . . . . . .
SENDER, Coolant Temp 300 Deg F M16 X 1.5 . . . . . . . . . . . . . . . . . . . . . .
GAUGE, Pressure Oil 0−100 Psi Electric . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENDER, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METER, amp ac/dc 0− 500 0−600 dc scale 2.5 in . . . . . . . . . . . . . . . . . . .
METER, volt ac/dc 0− 100 scale 2.5 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB, pointer .875 dia x .250 ID w/set screws plstc . . . . . . . . . . . . . . . . .
HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc . . . . . . . . . . . . . . . . .
BLANK, snap-in nyl .750 mtg hole blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLANK, snap−in nyl .250 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
2
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
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-4421 Page 84
3
1
2
4
5
6
10
9
8
7
805 259-A
Figure 13-6. Auxiliary Power Group, Export
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-6. Auxiliary Power Group, Export
. . . 1 . . . . . . . . . . . . +223121 . . Panel, Aux Power (Export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 144844 . . Stand−off, No 6−32 X .875 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . ELCB1 . . 222991 . . Circuit Breaker, Elcb 20a 220v 0.030a Trip . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 200910 . . Label, Warning Electric Shock And Moving Parts Ce . . . . . . . . . . . . . . . . . 1
. . . 5 . . . GFCI1 . . 151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . CB2 . . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 8 . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . RC1 . . . 176355 . . Rcpt, Str 2p3w 16a 220v Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+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-4421 Page 85
Hardware is common and
20
not available unless listed.
16
11
17
18
15
12
21
10
9
13
14
19
8
22
23
7
6
5
3
1
2
24
4
27
33
36
35
32
30 29
31
26
25
28
34
802 552-B
Figure 13-7. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-7. Generator (Figure 13-1 Item 93)
. . . 1 . . . . . . . . . . . . . 132 053 . . SCREW, .375−16x1.50 hex hd−pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . 183 387 . . WASHER, conical spring .406 ID x .875 OD pltd . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 195 911 . . ENDBELL, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . 143 220 . . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . 201 099 . . STATOR, exciter/gen pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . +215 011 . . STATOR, weld assembly complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . +♦216 318 . . STATOR, weld assembly complete (full kVA option) . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . 225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . 190 197 . . GUARD, generator wire mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . 172 674 . . SPRING, ext .240 OD x .041 wire x 3.500pld . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . 039 207 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . ROTOR . . 212 996 . . ROTOR, Generator Segmented Assy (Includes) . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . 210 824 . . . . ROTOR, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . 024 617 . . . . . . RING, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . 053 390 . . . . . . BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HUB, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 210 447 . . . . FAN, Rotor Assy Generator (Segmented) (includes) . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . 210 332 . . . . . . PLATE, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . 206 242 . . . . . . FAN, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . 049 026 . . . . . . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . 083 883 . . . . . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . 080 389 . . . . . . SCREW, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . .
. . . 20 . . . . . . . . . . . . . 197 487 . . . . FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4421 Page 86
6
6
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
4
10
10
8
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-7. Generator (Continued)
. . . 21 . . . . . . . . . . . . . 197 486
. . . 22 . . . . . . . . . . . . . 083 883
. . . 23 . . . . . . . . . . . . . 049 026
. . . 24 . . . . . . . . . . . . . 191 579
. . . . . . . . . . . . . . . . . . . 195 560
. . . 25 . . . . . . . . . . . . . 083 883
. . . 26 . . . . . . . . . . . . . 172 555
. . . 27 . . . . . . . . . . . . . 602 159
. . . 28 . . . . . . . . . . . . . 601 961
. . . 29 . . . . . . . . . . . . . . 602 211
. . . 30 . . . . . . . . . . . . . 139 341
. . . 31 . . . . . . . . . . . . . *190 823
. . . 32 . . . . . . . . . . . . . 208 469
. . . 33 . . . . . . . . . . . . . 189 142
. . . 34 . . . . . . . . . . . . . 602 242
. . . 35 . . . . . . . . . . . . . . 602 211
. . . 36 . . . . . . . . . . . . . 604 534
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
ADAPTER, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . .
SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . .
COVER, starter hole /Continental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GUARD, starter hole deutz 912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . .
SCREW, M10-1.5 x 50hexhd pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw . . . . . . . . . . . . .
SCREW, .312-18 x 2.25hexhd pln gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, lock .318 ID x 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRUSHHOLDER ASSEMBLY, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, flat .375IDx0.875odx.083t stl pld . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . .
SCREW, .312−18x1.25 hex hd−pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . .
1
4
4
1
1
6
6
6
4
6
4
3
3
1
2
2
2
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4421 Page 87
Hardware is common and
4
not available unless listed.
3
2
1
5
6
7
8
9
802 279-A
Figure 13-8. Main Rectifier Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-8. Main Rectifier Assembly (Figure 13-1 Item 117)
. . . . . . . . . . SR3 . . .
... 1 .............
... 2 .............
... 3 .............
... 4 .............
. . . 5 . . . . PC3 . . .
... 6 .............
... 7 .............
. . . 8 . D3, D5, D7
. . . 9 . D2, D4, D6
239 784
188 137
188 517
188 135
134 201
215 755
188 136
188 493
245 097
245 096
. . RECTIFIER, environmental high power (consisting of) . . . . . . . . . . . . . . . .
. . . . CONNECTION BOARD, rectifier AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUS BAR, connection board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ENCLOSURE, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSEMBLY, protection . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . INSULATOR, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HEAT SINK, rectifier al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . DIODE, rect 300 a 500v do−9 (straight) modified . . . . . . . . . . . . . . . . . .
. . . . DIODE, rect 300 a 500v do−9 (reversed) modified . . . . . . . . . . . . . . . . .
1
1
3
2
3
1
8
2
3
3
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4421 Page 88
Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Wiring Harnesses
....................
. . . . . . . . SR1, SR2 . .
. . . . . . . . . D1/C1 . . .
. . . . . . . . . . RC4 . . . .
CB11, CB12, CB13 . .
. . . . . . . . . . CR7 . . . .
....................
. . . . . . . . . . . S6 . . . . .
. . . . . . . . . . . S5 . . . . .
....................
....................
....................
. . . . . . . . . . . S2 . . . . .
....................
. . . . . . . . . . RC3 . . . .
. . . . . . . . . . RC1 . . . .
....................
....................
....................
238763
035704
189701
047483
139266
188636
148850
011622
011609
211292
211293
164617
021467
150316
158466
135133
092670
214932
214933
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Harness, control box, CC weld control (includes) . . . . . . . . . . . . . . . . .
Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diode/Capacitor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 15p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . .
Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . .
Relay, Ocv Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Tgl 3pdt 15a 125vac On−none−on Spd Term . . . . . . . . . . . . . . . .
Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . .
Conn, Pack 4p 1row Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . . . .
Clip, Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . .
Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . .
Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . .
Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
3
1
1
1
1
1
1
3
1
5
1
1
1
1
6
....................
CB11, CB12, CB13 . .
. . . . . . . . . . SR1 . . . .
....................
. . . . . . . . . . RC4 . . . .
. . . . . . . . . . RC3 . . . .
. . . . . . . . . . RC1 . . . .
....................
. . . . . . . . . . . S6 . . . . .
....................
. . . . . . . . . . . S5 . . . . .
. . . . . . . . . D1/C1 . . .
....................
....................
....................
....................
. . . . . . . . CB5, CB6 . .
....................
....................
....................
....................
238683
139266
035704
148850
047483
158466
135133
150316
193234
021467
011609
189701
193183
196602
196603
141450
093995
211292
211293
214932
214933
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Harness, control box, CV weld control (includes) . . . . . . . . . . . . . . . . .
Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . .
Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 15p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . .
Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . .
Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . .
Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Switch, Rotary 6 Posn Gold Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . .
Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . .
Diode/Capacitor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . .
Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
Supplementary Pro, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . .
Conn, Pack 4p 1row Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . .
Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3
1
1
1
1
1
6
1
1
1
1
1
4
1
1
2
1
1
1
6
....................
. . . . . . . . . . PLG3 . . . .
....................
. . . . . . . . . . PLG6 . . . .
215013
158465
187654
114063
..
..
..
..
Harness, weld control CC (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
....................
. . . . . . . . . . PLG6 . . . .
. . . . . . . . . . PLG8 . . . .
. . . . . . . . . PLG13 . . .
. . . . . . . . . . PLG3 . . . .
....................
....................
215207
114063
193184
147992
158465
187654
196602
..
..
..
..
..
..
..
Harness, weld control CV (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
6
OM-4421 Page 89
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Wiring Harnesses (Continued)
....................
. . . D10/C10, D11/C11,D12
. . . . . . . . . . CB10 . . . .
. . . . . . . . . . CR1 . . . .
....................
. . . . . . . . . . PLG4 . . . .
....................
....................
. . . . . . . . . . CR8 . . . .
232068
189701
190374
090104
148850
114062
212116
212117
197325
..
..
..
..
..
..
..
..
..
Harness, engine control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diode/Capacitor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . .
Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Rect Univ 084 15p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
3
3
1
. . . . . . . . . . . . . . . . . . . . 192558 . . Harness, range switch (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . . 148389 . . Conn,Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . . 1
....................
. . . . . . . . . . RC1 . . . .
. . . . . . . . . GFCI1 . . .
. . . . . . . . . . CB2 . . . .
201109
147632
151981
093996
..
..
..
..
Harness, receptacle auxiliary power (domestic models) (includes) .
Rcpt, Tw Lk Grd 2p3w 30a 250v *L6−30r . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . .
Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . .
1
1
1
1
. . . . . . . . . . . . . . . . . . . . 223132 . . Harness, receptacle auxiliary power (export models) (includes) . . . 1
. . . . . . . . . GFCI1 . . . 151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB2 . . . . 093996 . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 190259 . . Harness, brushholder (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . . 135134 . . Conn, Rect Univ 084 9p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187651 . . Seal, Wire Univ 9p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4421 Page 90
Effective January 1, 2010
(Equipment with a serial number preface of MA 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
* Spoolmate Spoolguns
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the 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 Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
* 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)
* 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 2010−01
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
© 2010 Miller Electric Mfg. Co.
2010−01
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