Miller | LF323133 | Owner Manual | Miller PIPEPRO 304 User manual

Miller PIPEPRO 304 User manual
OM-492
190 603BD
July 2005
Processes
MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
PipePro 304
™
Visit our website at
www.MillerWelds.com
File: Engine-Driven
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 4/05
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
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
7
7
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
4-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-5. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-2. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-3. Adding Coolant To Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-6. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-7. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-8. Remote 14 Receptacle RC14 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-9. Guidelines For Installing Customer-Supplied Emergency Air Shutdown Valve . . . . . . . . . . . . . . . . . . . 19
5-10. Operating Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-1. Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-2. Description Of Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-3. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-4. Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-5. Lift-Arc TIG Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-6. Recommendations For Extreme Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-1. Generator Power Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-2. Optional GFCI Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-3. Wiring Instructions For Optional 240 Volt, 3-Phase Twistlock Plug (NEMA L15-30P) . . . . . . . . . . . . . . 26
7-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . . . 27
TABLE OF CONTENTS
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Servicing Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Servicing Engine Lubrication And Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Replacing Throttle Solenoid TS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
28
29
30
31
32
33
34
35
36
37
38
42
44
44
45
46
47
54
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_3/05
Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see the
symbol, watch out, and follow the related instructions to avoid the
hazard. The safety information given below is only a summary of
the more complete safety information found in the Safety Standards listed in Section 1-7. Read and follow all Safety Standards.
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.
Only qualified persons should install, operate, maintain, and repair this unit.
Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
During operation, keep everybody, especially children, away.
Insulate work clamp when not connected to workpiece to prevent contact
with any metal object.
Do not connect more than one electrode or work cable to any single weld
output terminal.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all metal
parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats or covers
big enough to prevent any physical contact with the work or ground.
Do not use AC output in damp areas, if movement is confined, or if there is a
danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on unit.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing
wet clothing; on metal structures such as floors, gratings, or scaffolds;
when in cramped positions such as sitting, kneeling, or lying; or when there
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most
situations, use of a DC, constant voltage wire welder is recommended.
And, do not work alone!
Disconnect input power or stop engine before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
Properly install and ground this equipment according to its Owner’s Manual
and national, state, and local codes.
Always verify the supply ground — check and be sure that input power cord
ground wire is properly connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded receptacle outlet.
When making input connections, attach proper grounding conductor first −
double-check connections.
Frequently inspect input power cord for damage or bare wiring — replace
cord immediately if damaged — bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly with a separate cable.
Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged parts at
once. Maintain unit according to manual.
SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine.
Stop engine on inverter and discharge input capacitors according to
instructions in Maintenance Section before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use 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 airsupplied respirator. Always have a trained watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury
or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and
irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated
steel, unless the coating is removed from the weld area, the area is well
ventilated, and while wearing an air-supplied respirator. The coatings and
any metals containing these elements can give off toxic fumes if welded.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved
air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible
and invisible (ultraviolet and infrared) rays that can burn eyes
and skin. Sparks fly off from the weld.
Wear 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.
OM-492 Page 1
WELDING can cause fire or explosion.
HOT PARTS can cause severe burns.
Welding on closed containers, such as tanks, drums, or
pipes, can cause them to blow up. Sparks can fly off from the
welding arc. The flying sparks, hot workpiece, and hot
equipment can cause fires and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or fire. Check and be sure
the area is safe before doing any welding.
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.
Do not weld on closed containers such as tanks, drums, or pipes, unless
they are properly prepared according to AWS F4.1 (see Safety Standards).
Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and
causing electric shock, 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.
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.
NOISE can damage hearing.
Noise from some processes or equipment can damage
hearing.
Wear approved ear protection if noise level is high.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding operations.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
normally part of the welding process, be sure to treat them
carefully.
Protect compressed gas cylinders from excessive heat, mechanical
shocks, 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.
Remove any combustibles, such as a butane lighter or matches, from your
person before doing any welding.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
work and have a fire watcher and extinguisher nearby.
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.
FLYING METAL can injure eyes.
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 llift 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.
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.
1-3. Engine Hazards
MOVING PARTS can cause injury.
BATTERY EXPLOSION can BLIND.
Always wear a face shield, rubber gloves, and protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or adding fuel.
Do not add fuel while smoking or if unit is near any
sparks or open flames.
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
OM-492 Page 2
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
Stop engine before installing or connecting unit.
Have only qualified people remove 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.
HOT PARTS can cause severe burns.
Do not touch hot engine parts.
Allow cooling period before maintaining.
Wear protective gloves and clothing when working on
a hot engine.
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is cold to
avoid scalding.
Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise
in maintenance section or engine manual).
If the engine is warm, checking is needed, and there is no overflow tank,
follow the next two statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before completely removing cap.
ENGINE EXHAUST GASES can kill.
Use equipment outside in open, well-ventilated areas.
If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from flammables.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in required areas — see applicable codes.
1-4. Compressed Air Hazards
BREATHING COMPRESSED AIR can
cause serious injury or death.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
COMPRESSED AIR can cause injury.
Wear approved safety goggles.
Do not direct air stream toward self or others.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
Release air pressure from tools and system before
servicing, adding or changing attachments, or opening compressor oil drain or oil fill cap.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
Do not touch hot compressor or air system parts.
Let system cool down before touching or servicing.
READ INSTRUCTIONS.
Read Owner’s Manual before using or servicing unit.
Stop engine and release air pressure before
servicing.
Use only genuine Miller/Hobart replacement parts.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
Use lifting eye to lift unit and properly installed accessories only. Do not exceed maximum lift eye weight
rating (see Specifications).
Lift and support unit only with proper equipment and
correct procedures.
If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or stopping engine.
Do not let low voltage and frequency caused by low
engine speed damage electric motors.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before starting
to weld again.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to store,
move, or ship PC boards.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where
applicable.
FLYING SPARKS can cause injury.
OVERUSE can cause OVERHEATING.
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.
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer according to instructions supplied with trailer.
Sparks can cause fires — keep flammables away.
OM-492 Page 3
READ INSTRUCTIONS.
Use only genuine MILLER/Hobart replacement
parts.
Perform engine and air compressor (if applicable)
maintenance and service according to this manual
and the engine/air compressor (if applicable) manuals.
H.F. RADIATION can cause interference.
ARC WELDING can cause interference.
High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
Have only qualified persons familiar with electronic
equipment perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at
once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep spark
gaps at correct setting, and use grounding and shielding to minimize the
possibility of interference.
Electromagnetic energy can interfere with sensitive
electronic equipment such as microprocessors,
computers, and computer-driven equipment such as
robots.
Be sure all equipment in the welding area is electromagnetically compatible.
To reduce possible interference, keep weld cables as short as possible,
close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic
equipment.
Be sure this welding machine is installed and grounded according to this
manual.
If interference still occurs, the user must take extra measures such as
moving the welding machine, using shielded cables, using line filters, or
shielding the work area.
1-6. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1-7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, 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, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www.
sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
in Toronto 416-747-4044, website: www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices—phone for Region 5, Chicago, is
312-353-2220, website: www.osha.gov).
1-8. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
OM-492 Page 4
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 3/05
Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.
2-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Identifie un message de sécurité particulier.
Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du présent
manuel pour attirer votre attention et identifier les risques de danger.
Lorsque vous voyez un symbole, soyez vigilant et suivez les directives
mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les
normes de sécurité énumérées à la section 2-7 . Veuillez lire et respecter
toutes ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne doivent être
confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec la
pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec
tout objet métallique.
Une tension DC importante subsiste à l’intérieur des
onduleurs après avoir coupé l’alimentation.
Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants.
LES FUMÉES ET LES GAZ peuvent être
dangereux.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode
et le circuit de soudage sont sous tension dès que l’appareil
est sur ON. Le circuit d’entrée et les circuits internes de
l’appareil sont également sous tension à ce moment-là. En
soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des
galets d’entraînement et les pièces métalliques en contact avec le fil de soudage
sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un
danger.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas de
trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec
la pièce ou la terre.
Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire,
se servir de la fonction de télécommande si l’appareil en est équipé.
Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme: les endroits humides ou lorsque l’on porte des
vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions assises, à genoux et allongées; ou quand il y a
un risque important de contact accidentel avec la pièce ou le sol. Dans ces cas
utiliser les appareils suivants dans l’ordre de préférence: 1) un poste à souder
DC semi−automatique de type CV (MIG/MAG), 2) un poste à souder manuel
(électrode enrobée) DC, 3) un poste à souder manuel AC avec tension à vide
réduite. Dans la plupart des cas, un poste courant continu de type CV est recommandé. Et, ne pas travailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à
la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la
norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le
fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du
sectionneur ou que la fiche du cordon est raccordée à une prise correctement
mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise
à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé − remplacer le cordon immédiatement s’il est endommagé −
un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
une électrode provenant d’une autre machine.
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.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.
Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et les
instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant
un respirateur à alimentation d’air. Demander toujours à un surveillant dûment
formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des
accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir en présence de vapeurs et former des gaz hautement toxiques
et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé,
plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé
dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces
éléments peuvent dégager des fumées toxiques en cas de soudage.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Fermer l’alimentation du gaz protecteur en cas de non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
Le rayonnement de l’arc du procédé de soudage génère des
rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des
étincelles sont projetées pendant le soudage.
Porter un casque de soudage approuvé muni de verres filtrants approprié
pour protéger visage et yeux pendant le soudage (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.
OM-492 Page 5
LE SOUDAGE peut provoquer un incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels que des
réservoirs, tambours ou des conduites peut provoquer leur
éclatement. Des étincelles peuvent être projetées de l’arc de
soudure. La projection d’étincelles, des pièces chaudes et des équipements
chauds peut provoquer des incendies et des brûlures. Le contact accidentel de
l’électrode avec des objets métalliques peut provoquer des étincelles, une
explosion, un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
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).
Brancher le câble sur la pièce le plus près possible de la zone de soudage pour
éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.
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 porte-électrode
ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des gants en
cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches telles
qu’un allumeur au butane ou des allumettes.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B
pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
Le soudage, l’écaillement, le passage de la pièce à la bros-
se 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.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
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.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
Porter des protections approuvés pour les oreilles si le niveau sonore est trop élevé.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent d’abord
consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par
points.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs
mécaniques, 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
RENDRE AVEUGLE.
Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une intervention
sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.
Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier lieu.
Arrêter le moteur avant d’installer ou brancher l’appareil.
Seules des personnes qualifiées sont autorisées à enlever les portes, panneaux, recouvrements ou dispositifs de protection pour effectuer, s’il y a lieu,
des travaux d’entretien et de dépannage.
Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,
débrancher le câble négatif (−) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes
mobiles.
Remettre en place les panneaux ou les dispositifs de protection et fermer les
portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en
route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le
générateur.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrêter le moteur avant de vérifier le niveau de carburant
ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une
flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carburant
renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.
OM-492 Page 6
Porter des gants et des vêtements de protection pour travailler sur un
moteur chaud.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
DES ORGANES MOBILES peuvent provoquer des blessures.
Ne pas approcher les mains des ventilateurs, courroies et
autres pièces en mouvement.
Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
Ne pas toucher les parties chaudes du moteur.
Laisser l’ensemble se refroidir avant d’effectuer la
maintenance.
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.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Fermer l’alimentation du gaz protecteur en cas de non
utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
Ne pas placer l’appareil sur, au-dessus ou à proximité de
surfaces inflammables.
Tenir à distance les produits inflammables de l’échappement.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Empêcher les étincelles d’échappement du moteur de
provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé − voir
codes en vigueur.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
2-4. Dangers liés à l’air comprimé
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un incendie ou une explosion.
RESPIRER L’AIR COMPRIMÉ peut provoquer des blessures graves ou causer
la mort.
Ne pas couper ou gouger à proximité de produits inflammables.
Surveillez et garder un extincteur à proximité.
Ne pas utiliser l’air comprimé pour respirer.
Utiliser l’air comprimé seulement pour le coupage, gougeage et les outils pneumatiques.
DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.
L’AIR COMPRIMÉ peut provoquer
des blessures.
Porter des lunettes de sécurité approuvées.
Ne pas diriger le jet d’air vers d’autres ou soi-même.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provoquer des blessures.
2-5.
Relâcher la pression d’air de l’outillage ou du système avant d’effectuer la maintenance, avant de changer ou de rajouter des éléments ou avant d’ouvrir la
purge ou le bouchon de remplissage d’huile.
Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la maintenance.
LIRE LES INSTRUCTIONS.
Lisez le manuel d’instructions avant l’utilisation ou la
maintenance de l’appareil.
Arrêter le moteur et relâcher la pression avant d’effectuer la maintenance.
Utiliser uniquement des pièces de rechange Miller/Hobart.
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
LA CHUTE DE L’APPAREIL peut blesser.
Utiliser un œilleton de levage pour lever l’appareil et les
accessoires correctement installés. Ne pas dépasser
le poids nominal maximal de l’œilleton (voir les
spécifications).
Ne lever et ne soutenir l’appareil qu’avec de l’équipement
approprié et en suivant les procédures adéquates.
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 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.
LES ÉTINCELLES VOLANTES risquent
de provoquer des blessures.
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
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.
LE SURCHAUFFEMENT peut endommager le moteur électrique.
Ne pas toucher le compresseur ou d’autres éléments
du circuit air comprimé chauds.
UNE REMORQUE QUI BASCULE peut
entraîner 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.
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.
OM-492 Page 7
LIRE LES INSTRUCTIONS.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
Utiliser seulement les pièces de rechange d’origine.
Effectuer la maintenance du moteur et du compresseur
(si applicable) suivant ce manuel et le manuel du moteur/
compresseur (si applicable).
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
Le rayonnement haute fréquence (H.F.) peut provoquer
des interférences avec les équipements de
radio−navigation et de communication, les services de
sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées avec des
équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des sources
de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et un blindage pour réduire les interférences
éventuelles.
2-6.
Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des fumées et
des gaz qui contiennent des produits chimiques dont l’État de Californie
reconnaît qu’ils provoquent des malformations congénitales et, dans
certains cas, des cancers. (Code de santé et de sécurité de Californie,
chapitre 25249.5 et suivants)
Les batteries, les bornes et autres accessoires contiennent du plomb et
des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations
congénitales ou autres problèmes de procréation. Se laver les mains
après manipulation.
2-7.
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.
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.
Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :
de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet :
ternet : www.global.ihs.com).
www.csa-international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping, American Welding Society Standard AWS F4.1
de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.ansi.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection Standard for Fire Prevention During Welding, Cutting, and Other Hot
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de
Compressed Gas Association, 1735 Jefferson Davis Highway, Suite OSHA, Occupational Safety and Health Standards for General Industry,
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent
: www.cganet.com).
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
Code for Safety in Welding and Cutting, CSA Standard W117.2, de régionaux−−le téléphone de la région 5, Chicago, est 312-353-2220, site
Canadian Standards Association, Standards Sales, 178 Rexdale Internet : www.osha.gov).
2-8.
Information EMF
Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un
certain souci à propos de tels champs. Cependant, après avoir examiné
plus de 500 études qui ont été faites pendant une période de recherche
de 17 ans, un comité spécial ruban bleu du National Research Council a
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine ».
Toutefois, des études sont toujours en cours et les preuves continuent à
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux
champs électromagnétiques pendant le soudage ou le coupage.
Pour réduire les champs magnétiques sur le poste de travail, appliquer les
OM-492 Page 8
procédures suivantes :
1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la soudure.
En ce qui concerne les stimulateurs cardiaques
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder ou d’approcher des opérations de soudage. Si le médecin
approuve, il est recommandé de suivre les procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Symbol Definitions
Stop Engine
Fast
(Run, Weld/Power)
Fast/Slow
(Run/Idle)
Slow (Idle)
Start Engine
Panel/Local
Temperature
Fuel
Engine Oil
On
Check Valve
Clearance
Battery (Engine)
Engine
Read Operator’s
Manual
MIG (GMAW),
Wire
Stick (SMAW)
TIG (GTAW)
Circuit Breaker
Foot Control
Manual Control
Touch Start
(GTAW)
Pulsed
Positive
Negative
Alternating Current
(AC)
Output
Seconds
Protective Earth
(Ground)
Remote 14
Receptacle
Work Connection
Glow Plug
Electrode
Positive
Electrode Negative
High Temperature
h
Time
Do not switch while
welding
14
Wire Feed
A
s
Hours
V
Amperes
Volts
SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Welding
Mode
CC/DC
CV/DC
Rated
Welding
Output
300 A, 32 V,
60% duty
Cycle
Maximum
Open-Circuit
Voltage
99
Amperage
Range In
CC Mode
5 − 375 A
Voltage
Range In
CV Mode
Generator
Power Rating
10 − 34 V
Single-Phase,
12 kVA/kW
100/50 A,
A
120/240 V AC,
60 Hz
Fuel Capacity
Engine
13 gal (49 L)
Tank
Kubota DH905
Water-Cooled,
Three-Cylinder
Three-Cylinder,
Four-Cycle, 26 HP
Diesel Engine
OM-492 Page 9
4-2. Dimensions, Weights, and Operating Angles
Dimensions
Height
36 in (914 mm)
Width
24 in (610 mm)
Depth
59 in (1499 mm)
A
23-5/8 in (600 mm)
B
21-1/2 in (546 mm)
C
1 in (25 mm)
D
15-5/8 in (397 mm)
E
26-3/8 in (679 mm)
F
58-3/4 in (1492 mm)
G
13/32 in (10 mm) Dia.
A
B
C
Do not exceed tilt angles or engine could
be damaged or unit could tip.
D
G
4 Holes
F
Do not move or operate unit where it could
tip.
E
20°
20°
20°
20°
Weight
925 lb (420 kg)
Front Panel End
800 426
4-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Section 8-10), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
Exceeding duty cycle can
damage unit and void
warranty.
60% Duty Cycle
6 Minutes Welding
4 Minutes Resting
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
sduty1 5/95 / 196 698
OM-492 Page 10
4-4. Volt-Ampere Curves
Volt-ampere curves show minimum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall between curves shown.
A. CC Mode
ARC CONTROL
B. CV Mode
178 652 / 178 653
OM-492 Page 11
4-5. Fuel Consumption
7.57
2.00
6.62
1.75
5.67
1.50
4.73
1.25
3.78
1.00
2.84
0.75
1.98
0.50
0.95
0.25
3600 RPM
IDLE
0
U.S. GAL./HR.
LITERS/HR.
0
50
100 150 200 250 300 350 400 450 500
DC WELD AMPERES AT 100% DUTY CYCLE
193 458
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-492 Page 12
SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
Do not weld on base. Welding
on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.
Movement
Always securely fasten welding generator onto transport
vehicle or trailer and comply
with all DOT and other applicable codes.
Do not lift unit from end.
OR
Do not mount unit by supporting the base only at the four
mounting holes. Use crosssupports to adequately support unit and prevent damage
to base.
Location
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
OR
If unit does not have GFCI receptacles, use GFCI-protected
extension cord.
OR
Mounting:
1
Mounting
Cross-Supports
Mount unit on flat surface or use
cross-supports to support base.
Grounding:
2
3
4
Equipment Grounding Terminal
(On Front Panel)
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger insulated copper wire.
OR
Inadequate support.
Do not use flexible mounts.
1
2
Grounding
3
GND/PE
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
4
Airflow Clearance
Bed liners, shipping skids, and some running
gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding terminal to bare metal on the vehicle frame as shown.
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
install2 5/03 − Ref. 800 652 / Ref. 800 477-A / 803 274
OM-492 Page 13
5-2. Engine Prestart Checks
Check radiator coolant
level when fluid is low
in recovery tank.
Full
Capacity
w/Overflow Tank
6.4 qt (6 L)
Full
1/2 in
(13 mm)
Full
Diesel
Full
802 330-G
Check all fluids daily. Engine must be cold
and on a level surface. Unit is shipped with
10W30 engine oil.
Engine stops if oil pressure is too low or engine temperature is too high.
This unit has a low oil pressure shut-
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual. If
unburned fuel and oil collect in exhaust pipe
during run-in, see Section 10.
Fuel
Do not use gasoline. Gasoline will
damage engine.
Add fresh diesel fuel before starting engine
the first time (see maintenance label for
specifications). Fill fuel tank up to 1/2 in. (13
mm) from top to allow room for expansion.
Do not run out of fuel or air enters fuel system and causes starting problems. See engine manual to bleed air from fuel system.
OM-492 Page 14
Oil
After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Engine may use oil and wetstacking
may occur during run-in period.
Check oil several times daily during
run-in.
Coolant
Check coolant level in recovery tank before
starting unit the first time. Add coolant if
coolant is below bottom of radiator filler neck
(see Section 5-3 for radiator filling instructions.
Check coolant in recovery tank daily. If coolant is below Full level, add coolant until coolant level in tank is between Full and Low levels. If recovery tank coolant level was low,
also check coolant level in radiator (see
Section 5-3).
Engine coolant is a mixture of water and
ethylene glycol base antifreeze. A solution
of 50% antifreeze and 50% water must be
used in this engine. Do not use 100% antifreeze or severe damage will occur.
Keep radiator and air intake clean and free
of dirt.
Incorrect engine temperature can
damage engine. Do not run engine
without a properly working thermostat and radiator cap.
To improve cold weather starting:
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
operation (see Section 6-6).
5-3. Adding Coolant To Radiator
Stop engine and let cool.
Full
1
Capacity
w/Overflow Tank
6.4 qt (6 L)
Check coolant level according
to Section 5-2 before starting
this procedure.
If coolant level is below bottom of
radiator filler neck, add coolant as
follows:
1 Radiator Air Bleed Screw
Remove radiator air bleed screw.
Add coolant to radiator until coolant
is at bottom of filler neck. This ensures all air is purged from the system.
Reinstall screw and radiator cap.
Check coolant level in recovery
tank (see Section 5-2).
Engine coolant is a mixture of water
and ethylene glycol base antifreeze. A solution of 50% antifreeze
and 50% water must be used in this
engine. Do not use 100% antifreeze
or severe damage will occur.
Tools Needed:
Ref. 802 330-G
5-4. Connecting The Battery
Connect
negative (−)
cable last.
−
+
Tools Needed:
3/8, 1/2 in
Ref. 213 263-B / 802 330-G / Ref. S-0756-D
OM-492 Page 15
5-5. Installing Exhaust Pipe
Point exhaust pipe in desired
direction but always away from
front panel and direction of
travel.
Tools Needed:
1/2 in
802 173-B / Ref. 213 263-B
Notes
OM-492 Page 16
5-6. Connecting To Weld Output Terminals
Stick And TIG Welding
MIG And FCAW Welding
For Stick welding Direct Current Electrode
Positive (DCEP), connect electrode holder cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on
right.
For MIG welding Direct Current Electrode
Positive (DCEP), connect wire feeder
cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on
right.
For Stick and TIG Direct Current Electrode Negative (DCEN), connect electrode holder cable to Negative (−) terminal
on right and work cable to Positive (+) terminal on left.
For MIG and FCAW Direct Current Electrode Negative (DCEN), connect wire
feeder cable to Negative (−) terminal on
right and work cable to Positive (+) terminal on left.
Stop engine.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
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. Do not
place anything between weld cable terminal and copper bar. Make sure that the surfaces of the weld cable terminal and copper bar are clean.
Tools Needed:
3/4 in
1
3
2
6
Do not place
anything between
weld cable terminal
and copper bar.
4
5
Correct Installation
Incorrect Installation
80801 941 / Ref. 213 263-B / 802 174-E / 803 778-A
OM-492 Page 17
5-7. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Turn off power before
connecting to weld output terminals.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
Do not use worn, damaged, undersized, or
poorly spliced cables.
* This
10 − 100% Duty Cycle
chart is a general guideline and may not suit all applications. If cable(s) overheat (normally you can smell it), use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-E−
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
5-8. Remote 14 Receptacle RC14 Information
NOTE
Engine runs at weld/power speed whenever a device connected to the remote 14
receptacle is running.
Socket*
24 VOLTS AC
A
B
K
J
115 VOLTS AC
I
H
C L N
D M
G
E F
REMOTE
OUTPUT
CONTROL
A/V
AMPERAGE
VOLTAGE
802 174-G
*The remaining sockets are not used.
OM-492 Page 18
GND
Socket Information
A
24 volts ac. Protected by circuit breaker CB6.
B
Contact closure to A completes 24 volts ac
contactor control circuit.
I
115 volts ac. Protected by circuit breaker CB5.
J
Contact closure to I completes 115 volts ac
contactor control circuit.
C
Output to remote control; 0 to +10 volts dc, +10
volts dc in MIG mode.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control.
M
CC/CV select.
F
Current feedback; +1 volt dc per 100 amperes.
H
Voltage feedback; +1 volt dc per 10 output receptacle volts.
G
Circuit common for 24 and 115 volts ac circuits.
K
Chassis common.
5-9. Guidelines For Installing Customer-Supplied Emergency Air Shutdown Valve
A customer-supplied emergency air shutdown
valve can be installed to stop the engine immediately in emergency situations.
These guidelines show the typical installation of
a Gator ESD 175-275-L3 air shutdown valve.
Installation of other air shutdown valves may
differ from that shown. Contact the air shutdown valve manufacturer or a Factory Authorized Service Agent for additional installation
and operation information.
Stop engine, and let cool.
Disconnect battery negative (−) cable.
Open doors and remove side panels.
1 Air Cleaner
2 2 in (51 mm) Hose Clamp
3 1-3/4 x 2 in (44 x 51 mm) Rubber Hose
4 Air Shutdown Valve
(Gator ESD 175-275-L3)
5 1-3/4 x 16-1/2 in (44 x 419 mm) Flexible
Radiator Hose (NAPA Part No. FM68)
Use thick-walled rubber hose. Do not use
heater hose. (Heater hose could let dirt into
engine.)
6 Engine Air Inlet
7 Shutdown Control
8 42 in (1067 mm) Shutdown Control Cable
(Supplied By Gator)
9 Shutdown Valve Reset Lever
Install components as shown.
7
Be sure air shutdown valve is installed with air
flow arrow pointing toward air inlet. Use cable
ties to keep air shutdown system components
away from hot or moving parts.
Verify the emergency air shutdown system operates correctly. After testing, use reset lever to
reset air shutdown valve.
Reinstall side panels and close doors.
Reconnect battery negative (−) cable.
1
2
8
3
Mount on lower
front panel
9
4
5
7
6
803 390
OM-492 Page 19
5-10. Operating Engine Block Heater
Do not run engine while coolant heater is on.
Do not touch hot engine
block. Engine block gets hot
near heater.
1
2
1
Coolant Heater
2
Heater Plug
Use heater to maintain a constant
engine coolant temperature. See
table for heater specifications.
To turn on heater, connect heater
plug to a 120 volt ac grounded receptacle.
To turn off heater, disconnect plug.
Coolant Heater Specifications
Watts
Volts ±10%
Amps
400
120
3.3
Ref. 802 330 / 803 393
Notes
Start Your Professional
Welding Career Now!
OM-492 Page 20
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
Over 80,000 trained
since 1930!
SECTION 6 − OPERATING WELDING GENERATOR
6-1. Controls (See Section 6-2)
1
2
3
4
5
6
7
8
9
13
10
11
12
14
Ref. 213 263-B / 802 330-G
OM-492 Page 21
6-2. Description Of Controls (See Section 6-1)
The
fan motor is thermostatically
controlled and only runs when cooling is
needed.
Engine Lights
1 Engine Temperature Light
Light goes on and engine stops if engine temperature is too high.
Stop engine and fix trouble if Engine
Temperature light goes on.
2 Engine Oil Pressure Light
Light goes on and engine stops if oil pressure
is too low. Light goes on momentarily during
start-up but goes out when engine reaches
normal oil pressure.
Stop engine and fix trouble if Engine
Oil Pressure light stays on after startup.
3 Battery Charging Light
Light goes on if engine alternator is not charging battery. Engine continues to run.
Stop engine and fix trouble if Battery
Charging light goes on.
Engine Gauges
4 Engine Hour Meter
Use hour meter to help schedule routine maintenance.
5 Fuel Gauge
Weld Controls
6 Dig/Inductance Control
Control adjusts Dig when Stick mode is selected on mode switch. When control is set toward minimum, short-circuit amperage at low
arc voltage is the same as normal welding
amperage.
When set toward maximum, short-circuit amperage is increased at low arc voltage to assist with arc starts and help prevent the electrode from sticking while welding (see volt-ampere curves in Section 4-4).
Select setting best suited for application.
Control adjusts inductance when MIG or
V-Sense Feeder position is selected on the
OM-492 Page 22
mode switch. Inductance determines the
“wetness” of the weld puddle. When set toward maximum, “wetness” (puddle fluidity) increases.
Control is not functional when Pulsed MIG or
one of the TIG modes is selected.
7 Voltmeter
Meter displays weld voltage and help messages (see Sections 6-3 and 8-10).
8 Ammeter
Meter displays weld amperage and help messages (see Sections 6-3 and 8-10).
9 V/A (Voltage/Amperage) Adjustment
Control
10 Mode Switch
The Mode switch setting determines both the
process and output On/Off control (see Section 6-4). Source of control (panel or remote)
for the amount of output is selected by the V/A
Control switch.
For Air Carbon Arc (CAC-A) cutting and gouging, place switch in Stick position. For best results, place Dig/Inductance control in the maximum position.
11 V/A (Voltage/Amperage) Control Switch
And Remote 14 Receptacle
For front panel control, place switch in Panel
position and use the V/A Adjustment control.
For remote control, make connections to Remote 14 receptacle (see Section 5-8), and
place switch in Remote position. In most
modes, remote control is a percent of V/A Adjustment control setting (value selected on
V/A Adjustment control is maximum available
on remote). In the MIG mode, remote control
provides full range of unit output regardless of
V/A Adjust control setting.
Engine Starting Controls
12 Glow Plug Switch
Use switch to energize glow plugs for cold
weather starting. Glow plugs warm in about
six seconds and engine can be started (see
starting instructions following).
Do not use glow plug longer than 20
seconds.
13 Engine Control Switch
Use switch to start engine, select speed, and
stop engine. In Run/Idle position, engine runs
at idle speed at no load, and weld/power
speed under load. In Run position, engine
runs at weld/power speed.
To Start:
Do not use ether as a starting aid.
Using ether voids warranty.
Above 325 F: turn Engine Control switch to
Start. Release switch when engine starts and
Engine Oil Pressure light goes out.
If engine does not start, let engine come
to a complete stop before attempting restart.
Below 325 F: turn engine control switch to
Run/Idle position. Push Glow Plug switch up
and hold about six seconds. Turn Engine Control switch to Start. Release switch when engine starts and Engine Oil Pressure light goes
out.
See Section 6-6 for additional information on
cold weather operation.
If engine does not start, let engine come
to a complete stop before attempting restart.
To Stop: turn Engine Control switch to Off
position.
Push engine stop lever
to stop engine if
Engine Control switch does not work (see
item 14).
14 Engine Stop Lever
Use lever to stop engine if Engine Control
switch does not work.
6-3. Meter Functions
NOTE
The meters display the actual weld output values for approximately three seconds
after the arc is broken.
Mode
Meter Reading At Idle
V
Scratch
Start TIG
Meter Reading While Welding
A
80.0
85
Actual Volts
Actual Amps
V
A
V
A
7.0
85
85
Preset Amps
Actual Volts
Actual Amps
V
A
V
A
Blank
Preset Amps
Actual Volts
Actual Amps
V
A
V
A
24.5
250
Preset Volts
Blank
Actual Volts
Actual Amps
V
A
V
A
24.5
10.3
85
PPP
PPP
24.5
250
Pulse Display
Pulse Display
Actual Volts
Actual Amps
V
A
V
A
Blank
Preset Amps
Actual Volts
Actual Amps
V
A
V
A
85
CC
80.0
V-Sense
Feeder
10.3
Actual Volts
85
Stick
85
Preset Amps
TIG
Pulsed
MIG
10.3
A
Actual Volts (OCV)
Lift-Arc TIG
MIG
V
85
24.5
24.5
85
85
Actual Volts (OCV)
Preset Amps
Actual Volts
Actual Amps
V
A
V
A
24.5
250
Blank
Actual Volts
Actual Amps
80.0
Flashes OCV And Preset
6-4. Mode Switch Settings
NOTE
The Stick and CC modes provide the Adaptive Hot Start™ feature, which
automatically increases the output amperage at the start of a weld should the start
require it. This eliminates electrode sticking at arc start.
Mode Switch Setting
Process
Output On/Off Control
Scratch Start TIG
GTAW
Electrode Hot
Lift-Arc TIG
GTAW − See Section 6-5
Electrode Hot
TIG
GTAW With HF Unit, Pulsing Device, Or Remote Control
At Remote 14
MIG
GMAW
At Remote 14
Pulsed MIG
GMAW-P (Requires an external pulsing device.)
At Remote 14
CC
Stick (SMAW) With Remote On/Off
At Remote 14
Stick
SMAW
Electrode Hot
V-Sense Feeder
MIG (GMAW) With Voltage Sensing Wire Feeder
Electrode Hot
OM-492 Page 23
6-5. Lift-Arc TIG Procedure
With Mode Switch in the Lift-Arc
TIG position, start an arc as follows:
1
2
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece at weld start point, hold
electrode to workpiece for 1-2
seconds, and slowly lift electrode.
An arc will form when electrode is
lifted.
1−2
Seconds
“Touch”
1
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece without overheating, sticking, or getting
contaminated.
Do NOT Strike Like A Match!
Ref. S-156 279
6-6. Recommendations For Extreme Cold Weather Operation
For more information on operating in
cold
weather, contact the nearest Factory Authorized Service Agent or Kubota Service
Center.
Fuel
Use an arctic-grade diesel fuel and keep
fuel tank at least half full to prevent fuel
lines from draining back into tank.
Do not use gasoline or kerosene.
Do not use fuel additives.
Battery
Replacement Battery Rating: 12 Volt, 535
CCA (minimum) 90 RSV Group 55.
Check connections at battery, starter, and
engine block. Inspect battery cables for
abrasion and wear, and verify the battery
is secured.
Consider installing easily-accessible battery booster leads (0 or 00 AWG) to provide easy connection to a service truck’s
battery.
Oil
Use 10W30 oil when operating at ambient
temperatures above -4° F (−20° C).
Use 5W30 oil when operating at ambient
temperatures above -13° F (−25° C).
Operating at extremely low temperatures
thickens engine oil and reduces cranking
speed. Contact a Factory Authorized Service Agent or Kubota Service Center for
information on using 0W20 oil in these
conditions. Low temperature oil must be
replaced as ambient operating temperatures increase.
Be sure the cooling system is completely
filled with a 50/50 antifreeze/water mix
(open the radiator vent when filling). Do
not mix antifreeze and water solution in
the overflow tank. Use a premixed 50/50
antifreeze/water solution to “top off” overflow tank. Use caution if rerouting cooling
lines. Engine damage due to lack of
coolant or incorrect coolant mix is not
covered by the warranty.
OM-492 Page 24
Boost the starting capability of the battery
by using a battery heater.
Operating
To reduce crankcase condensation and
breather tube freezing problems, allow
engine to reach normal operating temperature as quickly as possible.
Crankcase breather tubes will collect
condensation and freeze if the hose is improperly routed. The breather tube should
be free of sharp bends and kinks. A
blocked breather tube will cause excessive crankcase pressure that will blow out
the safety plug, oil seals, or dipstick. Contact a Factory Authorized Service Agent
to obtain a shorter breather hose that is
less likely to kink.
Inspect the routing and condition of the
breather tube frequently. Reroute or replace the hose if necessary.
For continuous use in extreme cold, block
the cooling holes in the base to reduce air
flow through the radiator and achieve
higher engine temperature. Close off the
base inlet vents only if the engine coolant
or oil temperatures can be monitored to
ensure they remain within the specified
limits.
To obtain warmer air for combustion, turn
the air cleaner inlet away from the inlet
vents, and seal the inlet vents.
If operating in cold weather all the time,
consider replacing the existing radiator
cooling fan with a smaller fan that draws
less air through the radiator. Operation in
warmer temperatures would require an
additional “booster” electric fan to adequately cool the engine.
Starting
Do not use ether.
Use the engine block heater to maintain
engine temperature above ambient temperature.
Use the glow plugs for 20−30 seconds before starting. As a preseason check,
make sure the glow plugs are working
properly.
Disconnect all unnecessary loads from
generator ac receptacles when starting.
Coolant
A 50/50 antifreeze/water mix protects engine to -34° F (−37° C). If operating at even
lower temperatures, contact a Factory
Authorized Service Agent or Kubota Service Center for coolant information.
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. Generator Power Receptacles And Circuit Breakers
5
1
2
3
7
6
4
8
SIMULTANEOUS WELDING AND AUXILIARY POWER
Weld
Current
In Amperes
Total
Power
In Watts
350
300
250
200
150
100
50
0
11900
9600
7500
5600
3900
2400
1100
0
120 V
Single-Phase Three-Phase
Receptacle
240 V
240 V
Amperes
Receptacle
Receptacle
Amperes
Amperes
−
16
38
40
40
40
40
40
−
5
15
30
35
40
45
50
−
4
10
13
19
23
26
30
213 263-B
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Generator power decreases as weld
current increases.
1
240 V 50 A AC Receptacle RC1
RC1 supplies 60 Hz single-phase power at
weld/power speed. Maximum output is 12
kVA/kW.
2
120 V 20 A AC Duplex Receptacle
RC2
3
120 V 20 A AC Duplex Receptacle
RC3
RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum out-
put from RC2 or RC3 is 2.4 kVA/kW.
4
240 V 30 A, AC Twistlock Receptacle
RC4
RC4 supplies 60 Hz three-phase power at
weld/power speed. Maximum output is 12
kVA/kW.
5
Circuit Breaker CB1
CB1 protects RC1, RC2, and RC3 from
overload. If CB1 opens, RC1, RC2, and
RC3 do not work. Place switch in On position to reset breaker.
6
Circuit Breakers CB2 And CB3
CB2 protects RC2 and CB3 protects RC3
from from overload. If CB2 or CB3 opens,
the receptacle does not work. Press button
to reset breaker. Place switch in On position to reset breaker.
7 Circuit Breaker CB4
CB4 protects RC4 from overload. If CB4
opens, the receptacle does not work. Place
switch in On position to reset breaker.
If a breaker continues to open, contact
Factory Authorized Service Agent.
Combined output of all receptacles limited
to 12 kVA/kW rating of the generator.
EXAMPLE: If 13 A is drawn from RC2 and
RC3, only 37 A is available at RC1:
2 x (120 V x 13 A) + (240 V x 28 A) = 12
kVA/kW
8 Generator Power While Welding
Table
OM-492 Page 25
7-2. Optional GFCI Receptacles And Circuit Breakers
If unit does not have GFCI
receptacles, use GFCI-protected extension cord.
1
Generator power decreases as
2
weld current increases.
1
120 V 20 A AC GFCI Duplex
Receptacle GFCI-2
2
120 V 20 A AC GFCI Duplex
Receptacle GFCI-3
GFCI-2 and GFCI-3 supply 60 Hz
single-phase power at weld/power
speed. Maximum output from
GFCI-2 or GFCI-3 is 2.4 kVA/kW.
Circuit breaker protection is the
same as standard receptacles.
If a ground fault is detected, the GFCI
Reset button pops out and the circuit
opens to disconnect the faulty equipment. Check for damaged tools,
cords, plugs, etc. connected to the
receptacle. Press button to reset receptacle and resume operation.
At least once a month, run en-
gine at weld/power speed and
press Test button to verify GFCI
is working properly.
Ref. ST-207 554-A
7-3. Wiring Instructions For Optional 240 Volt, 3-Phase Twistlock Plug (NEMA L15-30P)
1
5
4
1
240 V AC Three-Phase, 30 A,
3P4W Twistlock Plug
2
Load 1 (Brass) Terminal (X)
3
Load 2 (Brass)Terminal (Y)
4
Load 3 (Brass) Terminal (Z)
5
6
Ground (Green) Terminal (G)
Cord Grip
Strip cord jacket back enough to separate conductors.
2
240V
240V
6
240V
3
Strip conductors enough to make
good contact with plug terminals.
Make plug connections and reinstall
cord grip.
Tighten cord grip assembly screws.
Do not overtighten.
Tools Needed:
Plug2 7/99 − 802 437
OM-492 Page 26
7-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
1
7
Current Available in Amperes
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
240 V
Each 120 V Duplex
Receptacle*
Receptacle
0
5
10
15
20
25
30
35
40
Plug Wired for 120/240 V,
3-Wire Load
20
20
20
20
20
15
10
5
0
V x A = Watts
1
3
4
120V
2
Plug Wired for 240 V, 2-Wire
Load
3
Neutral (Silver) Terminal
4
Load 1 (Brass)Terminal
5
Load 2 (Brass) Terminal
6
Ground (Green) Terminal
7
Amperes Available using
120/240 V Plug
5
120V
240V
6
*One 240 V load or two 120 V loads.
Tools Needed:
2
3
4
240V
6
5
240 V AC
120 V AC
120 V AC
plug1 11/03 − 120 813-D
OM-492 Page 27
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING
8-1. Maintenance Label
OM-492 Page 28
8-2. Routine Maintenance
Note
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Stop engine before maintaining.
Recycle
engine
fluids.
See also Engine Manual and Maintenance Label.
Service engine more often if used in severe conditions.
*
To be done by Factory Authorized Service Agent.
Every 8 h
Full
Wipe Up
Spills.
Check Fluid
Levels. See
Section 5-2.
FUEL
WATER
Drain Water From
Fuel System. See
Section 8-5.
Recovery Tank
Every 20 h
Check and clean optional
spark arrestor screen.
See Section 8-3.
Every 50 h
Clean and
tighten weld
terminals.
Check fuel lines
and
connections.
See Section 8-5.
Every 100 h
Check air cleaner
hoses for cracks
and loose clamps.
Service air filter element.
See Section 8-4.
Clean and
tighten battery
connections.
5/16 in.
(8 mm)
Check belt tension.
Every 200 h
Change oil filter.
Section
8-5
maintenance label.
Change oil. See Section 8-5
and maintenance label.
See
and
Replace primary
fuel filter. See
Section 8-5.
Check radiator
hoses
and
clamps.
Replace unreadable
labels.
Every 400 h
Replace secondary
fuel filter. See
Section 8-5.
OM-492 Page 29
Every 500 h
Replace fan belt.
Drain sludge from
fuel tank.
Flush radiator.
FUEL
SLUDGE
Repair or replace
cracked cables.
Every 800 h
Check valve
clearance.*
Every 1000 h
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
Service welding generator
brushes and slip rings. Service
more often in dirty conditions.*
OR
Every 2000 h
Replace fuel
lines
and
clamps. See
Section 8-5.
Replace
radiator
coolant and hoses.
See Section 8-6.
8-3. Servicing Spark Arrestor
Stop engine and let cool.
1
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
Start engine and run several minutes to blow out cleanout hole. If
nothing blows out of hole, briefly
cover end of exhaust pipe with fireproof material.
1
Tools Needed:
1/4 in
Ref. 213 263-B-B / 802 743 / Ref. 802 656
OM-492 Page 30
8-4. Servicing Air Cleaner
Stop engine.
1
2
3
Do not run engine without air
cleaner or with dirty element. Engine damage caused by using a
damaged element is not covered
by the warranty.
4
The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
5
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
Keep nozzle
2 in (51 mm)
from element.
1
Housing
2
Safety Element (Optional)
3
Primary Element
4
Dust Cap
5
Dust Ejector
To clean air filter:
Blow
Inspect
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-492 Page 31
8-5. Servicing Engine Lubrication And Fuel Systems
4
FLOW
5
4
1
6
7
3
8
Tools Needed:
2
9/16 in
Ref. 213 263-B / 802 330-G / S-0842
Stop engine and let cool.
1
Oil Filter
2
Oil Drain Valve
3
4
5
1/2 ID x 12 in Hose
Fuel Line
Primary Fuel Filter
6
To drain water from fuel system:
To change coolant:
Open secondary fuel filter petcock and
drain water into metal container. Close petcock when water-free fuel flows.
Change coolant according to engine
manual.
To change fuel filters:
Secondary Fuel Filter
Install new primary fuel filter as shown.
7
Petcock
8
Fuel Tank Sludge Drain
Replace secondary fuel filter according to
engine manual.
To change oil and filter:
Replace fuel lines if cracked or worn.
Pull oil drain hose through access hole in
base. Change engine oil and filter according
to instructions in engine manual.
Wipe up any spilled fuel.
Close valve and valve cap before adding oil and running engine.
Fill crankcase with new oil to full mark on
dipstick (see Section 5-2).
OM-492 Page 32
After servicing, start engine and
check for fuel leaks.
Stop engine, tighten connections as
necessary, and wipe up fuel.
Run engine until engine reaches normal operating temperature. Loosen air bleed
screw to remove air from cooling system.
Tighten screw.
Check coolant level in recovery tank. Add
coolant if necessary.
To drain sludge from fuel tank:
Put metal container under drain, and remove sludge drain plug. Reinstall plug
when done.
8-6. Servicing Engine Cooling System
Stop engine and let cool.
1
Radiator Draincock
2
Radiator Cap
3
Radiator Air Bleed Screw
Change coolant according to engine
manual. Add coolant according to Section 5-3).
Run engine until engine reaches normal
operating temperature. Loosen air bleed
screw to remove air from cooling system.
Tighten screw.
Check coolant level in recovery tank. Add
coolant if necessary
1
3
2
802 330-G / 802 581
OM-492 Page 33
8-7. Replacing Throttle Solenoid TS1
Stop engine, and let cool.
Disconnect battery, negative
(−) cable first.
Remove right side engine panel.
1
2
3
4
5
6
7
8
Plug PLG39/Receptacle RC39
Throttle Solenoid TS1
Shoulder Bolt And Nut
Throttle Link
Throttle Solenoid Plunger Rod
Jam Nut
Throttle Arm
Throttle Arm Stop Screw
Disconnect solenoid plug PLG39
from wiring harness receptacle
RC39.
Remove shoulder bolt and nut from
throttle link.
Remove solenoid from mounting
bracket.
Note how much thread is visible on
solenoid plunger rod. Loosen jam nut
just enough so throttle link can be removed from solenoid rod.
Install throttle link on new solenoid
plunger rod. Turn link until the same
amount of thread will be visible on
plunger rod when the jam nut is tightened. (Do not tighten jam nut yet.)
Mount solenoid on bracket. Move solenoid plunger manually to align slot
in throttle link with hole in throttle arm.
Insert shoulder bolt through slot/hole
and secure with nut.
Be
sure solenoid plunger rod
pulls all the way in “bottoms”
when energized. If plunger rod
does not pull all the way in, readjust throttle link.
1
8
Throttle arm
2
7
should not contact
stop screw when solenoid is energized. If necessary, adjust
throttle link to create gap between throttle arm and stop
screw.
Tighten jam nut on solenoid plunger
rod. Verify all other hardware is tight.
Connect solenoid plug PLG39 to wiring harness receptacle RC39.
Reconnect battery, negative (−) lead
last.
Check engine speeds and adjust if
necessary according to Section 8-8.
Reinstall side panel.
5
6
4
3
Tools Needed:
7/16, 3/8, 1/2 in
10 mm
3/16 in
802 330-B
OM-492 Page 34
8-8. Adjusting Engine Speed
After tuning engine, check engine
speeds with a tachometer (see table).
If necessary, adjust speeds as follows:
2500 rpm (41.6 Hz)
Start engine and run until warm. Turn
V/A control to max.
3750 Max (62.5 Hz)
Adjusting Idle Speed
Idle speed is factory set and normally
does not not require adjustment unless
the governor/injector pump or throttle
solenoid is replaced.
1
2
3
4
Throttle Link
Throttle Solenoid Plunger Rod
Jam Nut
Throttle Arm Stop Screw
Turn Engine Control switch to Run/Idle
position. Loosen jam nut and turn solenoid rod clockwise (into throttle link) to
decrease idle speed. Turn rod counterclockwise to increase idle speed.
Tighten nut.
Be sure solenoid plunger rod pulls
all the way in “bottoms” when energized. If plunger rod does not
pull all the way in, readjust rod and
throttle link.
Throttle arm
should not contact
stop screw when solenoid is energized. If necessary, adjust throttle
link to create gap between throttle
arm and stop screw.
Adjusting Weld/Power Speed
5
6
7
Throttle Solenoid
Weld Speed Jam Nut
Adjustment Screw
Turn Engine Control switch to Run
position. Loosen nut and turn screw
counterclockwise to increase speed.
Turn screw clockwise to decrease
speed. Tighten nut.
6
Using Engine Stop Lever
7
8
Engine Stop Lever
Use lever to stop engine if Engine Control switch does not work.
4
5
8
2
3
1
Tools Needed:
10 mm
802 330-B
OM-492 Page 35
8-9. Overload Protection
Tools Needed:
3/8 in
1
2
Stop engine.
When a circuit breaker opens,
it usually indicates a more serious problem exists. Contact
Factory Authorized Service
Agent.
1 Circuit Breaker CB5
CB5 protects the 115 volt ac output
to Remote 14 receptacle RC14. If
CB5 opens, 115 volt ac output to
RC14 stops.
2 Circuit Breaker CB6
CB6 protects the 24 volt ac output
to Remote 14 receptacle RC14. If
CB6 opens, 24 volt ac output to
RC14 stops.
Press button to reset breaker.
3 Circuit Breaker CB7
4 Circuit Breaker CB8
5 Circuit Breaker CB10
CB7 protects the engine glow plug
from overload. If CB7 opens, the
glow plug does not work and engine
may not start in cold weather.
Check continuity and connections
of engine glow plug.
CB8 protects the engine wiring system from overload. If CB8 opens,
the engine will not crank. Check
battery, starter, and engine control
switch.
CB10 protects the engine fuel solenoid from overload. If CB10 opens,
the engine cranks but does not
start. Check fuel solenoid FS1 for
obstructions.
5
4
3
Ref. 213 263-B-B / 802 174-E / 802 175-D
OM-492 Page 36
8-10. Voltmeter/Ammeter Help Displays
1
2
3
4
5
V
A
HE.L
P−0
V
A
HE.L
P−1
V
A
HE.L
P−2
V
A
HE.L
P−3
V
A
HE.L
P−4
6
7
8
9
10
V
A
HE.L
P−5
V
A
HE.L
P−6
V
A
HE.L
P−7
V
A
HE.L
P−8
V
A
HE.L
P−9
802 174-G
Use the voltmeter/ammeter help displays to
help determine the cause of no weld output.
When a help display is shown, the inverter
module weld output has stopped but the engine continues to run. Correct the problem
before resuming operation.
3
Help 2 Display
Indicates a malfunction in the thermal protection circuitry located on the left side of the unit.
If this display is shown, contact a Factory Authorized Service Agent.
The display screen resets when the fault is
corrected.
4
All directions are in reference to the front
of the unit. All circuitry referred to is located inside the inverter module.
Indicates the left side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-3). Operation will
continue when the unit has cooled.
1
Help 0 Display
5
Indicates a shorted thermistor RT2 on the left
side of the unit. If this display is shown, contact a Factory Authorized Service Agent.
2
Help 1 Display
Indicates a malfunction in the primary power
circuit possibly caused by applying a high
weld load at idle speed. Turn Engine Control
switch to Run position. If problem continues,
contact a Factory Authorized Service Agent.
Help 3 Display
Help 4 Display
Indicates a malfunction in the thermal protection circuitry located on the right side of the
unit. If this display is shown, contact a Factory
Authorized Service Agent.
6
Help 5 Display
Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-3). Operation will
continue when the unit has cooled.
7
Help 6 Display
Indicates that the input voltage is too low and
the unit has automatically shut down. Operation will continue when the voltage is within the
acceptable lower range limit (15% below the
applicable input voltage). If this display is
shown, have a Factory Authorized Service
Agent check the power generator output voltage.
8
Help 7 Display
Indicates that the input voltage is too high and
the unit has automatically shut down. Operation will continue when the voltage is within the
acceptable upper range limit (15% above the
applicable input voltage). If this display is
shown, have a Factory Authorized Service
Agent check the power generator output voltage.
9
Help 8 Display
Indicates a malfunction in the secondary power circuit of the unit. If this display is shown,
contact a Factory Authorized Service Agent.
10 Help 9 Display
Indicates a shorted thermistor RT1 on the
right side of the unit. If this display is shown,
contact a Factory Authorized Service Agent.
OM-492 Page 37
8-11. Troubleshooting
A. Welding
Trouble
No weld output.
Remedy
Check control settings.
Check weld connections.
Disconnect equipment from generator power receptacles during start-up.
If using remote control, be sure mode switch is in a position that provides output control at Remote 14
receptacle (see Sections 5-8 and 6-1).
Check, repair, or replace remote control.
Unit overheated. Allow unit to run so fan cools unit (see Section 4-3).
Have Factory Authorized Service Agent check brushes, slip rings, power board PC7, voltage regulator
board PC8, interconnecting board PC2, and control board PC1.
Ammeter and voltmeter do not work
after unit has run out of fuel.
Restart the engine.
Low weld output.
Check control settings.
Place V/A Control switch in Panel position, or move switch to Remote position and connect remote
amperage/voltage control to Remote 14 receptacle RC14 (see Section 5-8).
Check and clean air cleaner as necessary (see Section 8-4).
Check engine speed, and adjust if necessary (see Section 8-8).
If using remote control, be sure mode switch is in a position that provides output control at Remote 14
receptacle RC14 (see Sections 5-8 and 6-1).
Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, interconnecting board PC2, and control board PC1.
See engine manual.
High weld output.
Check control settings.
Check engine speed, and adjust if necessary (see Section 8-8).
Check for obstructed movement of throttle solenoid linkage.
Have Factory Authorized Service Agent check voltage regulator board PC8 and control board PC1.
Weld output cannot be adjusted.
Check position of V/A Control switch (see Section 6-1).
Have Factory Authorized Service Agent check voltage regulator board PC8 and control board PC1.
Erratic weld output.
Check control settings.
Clean and tighten connections both inside and outside unit.
Check and secure lead connections to A/V control.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Use dry, properly stored electrodes.
Check engine speed, and adjust if necessary (see Section 8-8).
Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, interconnecting board PC2, and control board PC1.
OM-492 Page 38
Trouble
Remedy
Remote contactor control does not
activate contactor.
Check and tighten connections to Remote 14 receptacle RC14 (see Section 5-8).
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Welding arc.
Use proper size tungsten for welding amperage.
Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Wandering arc − poor control of arc
direction.
Reduce gas flow rate.
Select proper size tungsten. Properly prepare tungsten.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
No 115 volt ac output at Remote 14 receptacle RC14.
Reset circuit breaker CB5 (see Section 8-9).
No 24 volt ac output at Remote 14 receptacle RC14.
Reset circuit breaker CB6 (see Section 8-9).
B. Generator Power
Trouble
No power output.
Remedy
Reset circuit breakers (see Section 7-1).
Have Factory Authorized Service Agent check brushes, slip rings, power board PC7, voltage regulator
board PC8, interconnecting board PC2, and control board PC1.
Low power output.
Check air cleaner, and clean or replace element if necessary.
Check engine speed, and adjust if necessary (see Section 8-8).
See engine manual.
High power output.
Check engine speed, and adjust if necessary (see Section 8-8).
Erratic power output.
Check receptacle wiring and connections.
Check governor according to engine manual.
Have Factory Authorized Service Agent check brushes, slip rings, power board PC7, voltage regulator
board PC8, interconnecting board PC2, and control board PC1.
OM-492 Page 39
C. Engine
Trouble
Engine will not crank.
Remedy
Reset circuit breaker CB8 (see Section 8-9).
Check battery voltage.
Check battery connections and tighten if necessary.
Have Factory Authorized Service Agent check Engine Control switch S2.
Engine cranks, but does not start.
Check fuel level (see Section 5-2).
Open fuel valve (see Section 5-2).
Check oil level (see Section 5-2). Engine will not start if oil pressure is low.
Reset circuit breaker CB10 (see Section 8-9).
Check coolant level and fan belt (see Section 5-2 and engine manual). Engine will not start if coolant
temperature is high.
Use Glow Plug switch if unit does not start in cold weather. If unit still does not start, reset circuit
breaker CB7 (see Section 8-9).
Service primary and secondary fuel filters (see Section 8-5).
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Bleed air from fuel system according to engine manual.
Reset customer-supplied emergency air shutdown valve (if equipped) (see Section 5-9).
Have Factory Authorized Service Agent check low oil pressure switch S5, engine coolant temperature switch S4, and control relay CR1.
See engine manual.
Engine starts, but stops when Engine
Control switch returns to Run position.
Check oil level (see Section 5-2). Engine will not start if oil pressure is too low.
Check coolant level and fan belt (see Section 5-2 and engine manual). Engine will not start if engine
temperature is too high.
Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see engine manual).
Have Factory Authorized Service Agent check low oil pressure switch S5, engine coolant temperature switch S4, Engine Control switch S2, control relay CR1, and voltage regulator board PC8.
Engine does not stop.
Stop engine by pushing down engine stop lever (see Section 5-2) or closing fuel valve (see Section
5-2). After stopping engine, adjust fuel solenoid linkage (see engine manual).
Engine stopped during normal
operation.
Check fuel level (see Section 5-2).
Open fuel valve (see Section 5-2).
Check oil level (see Section 5-2). Engine stops if oil pressure is too low.
Check coolant level and fan belt (see Section 5-2 and engine manual). Engine stops if engine temperature is too high.
Bleed air from fuel system according to engine manual.
Have Factory Authorized Service Agent check low oil pressure switch S5 and engine coolant temperature switch S4.
Battery discharges between uses.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator according to engine manual.
OM-492 Page 40
Trouble
Engine does not go to low (idle) speed
with Engine Control switch in Run/Idle
position.
Remedy
Be sure Engine Control switch S2 is in Run/Idle position.
Remove all weld and generator power loads.
Turn off remote device connected to Remote 14 receptacle RC14 (see Section 5-8).
Check for obstructed movement of throttle solenoid linkage.
Have Factory Authorized Service Agent check voltage regulator board PC8 and current transformer
CT1.
Engine does not go to high (run) speed
when generator power or large weld
load is applied with Engine Control
switch in Run/Idle position.
Place Engine Control switch in the Run position. Have Factory Authorized Service Agent check unit.
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine (see Section 10 and engine manual).
Coolant recovery tank continuously
overflows.
Bleed air from radiator, and replace lost coolant (see Section 5-3).
Notes
OM-492 Page 41
SECTION 9 − ELECTRICAL DIAGRAMS
Figure 9-1. Circuit Diagram For Welding Generator
OM-492 Page 42
212 633-E
OM-492 Page 43
SECTION 10 − RUN-IN PROCEDURE
run_in4 8/01
10-1. Wetstacking
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
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.
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
1
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-492 Page 44
10-2. Run-In Procedure Using Load Bank
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Keep exhaust and pipe away
from flammables.
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
4
2
1
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or generator auxiliary power receptacle.
2
Welding Generator
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe
correct
polarity.
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator V/A control so load
equals 225 amps at 30 volts.
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
3
Check oil level frequently during run-in; add oil if needed.
After one hour (minimum) place V/A
control in minimum position, then
turn off load bank to remove load.
Run engine several minutes at no
load.
Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0683
OM-492 Page 45
10-3. Run-In Procedure Using Resistance Grid
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Keep exhaust and pipe away
from flammables.
6
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
2
1
1 Resistance Grid
Use grid sized for generator rated
output.
Turn Off grid.
2
Welding Generator
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connectors (polarity is not important).
4
Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several
minutes.
3
5
Set grid switches and then adjust
generator V/A control so load
equals 225 amps at 30 volts.
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
Check oil level frequently dur-
4
ing run-in; add oil if needed.
+
After one hour (minimum), place
V/A control in minimum position,
then shut down grid to remove load.
Run engine several minutes at no
load.
Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
OM-492 Page 46
SECTION 11 − GENERATOR POWER GUIDELINES
NOTE
The views in this section are intended to be representative of all engine-driven
welding generators. Your unit may differ from those shown.
11-1. Selecting Equipment
1
2
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
Do not use 2-prong plug unless equipment is double insulated.
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577
11-2. Grounding Generator To Truck Or Trailer Frame
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
1
2
1
GND/PE
3
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
2
3
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Electrically bond generator
frame to vehicle frame by
metal-to-metal contact.
Bed liners, shipping skids, and some running
gear insulate the welding generator from the vehicle frame. Always connect a ground wire from
the generator equipment grounding terminal to
bare metal on the vehicle frame as shown.
S-0854
OM-492 Page 47
11-3. Grounding When Supplying Building Systems
1
1
2
Equipment Grounding
Terminal
Grounding Cable
2
GND/PE
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
2
Use ground device as stated
in electrical codes.
3
ST-800 576-B
11-4. How Much Power Does Equipment Require?
1
3
2
1
VOLTS 115
AMPS 4.5
Hz
60
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
Non-Resistive Load
Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running
(see Section 11-8).
3
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
AMPERES x VOLTS = WATTS
EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-492 Page 48
11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
11-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
OM-492 Page 49
11-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
OM-492 Page 50
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
11-8. Power Required To Start Motor
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
1
2
3
4
2
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welding generator amperage output must be at least twice the
motor’s running amperage.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230
HP = 1/4
Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A Starting the motor requires 12.2 amperes.
230
S-0624
11-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-492 Page 51
11-10. Typical Connections To Supply Standby Power
Properly install and ground this equipment according to
its Owner’s Manual and national, state, and local codes.
1
2
Utility
Electrical
Service
3
Transfer Switch
4
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
5
Essential
Loads
Have only qualified persons perform
these connections according to all
applicable codes and safety practices.
Switch transfers the electrical load from
electric utility service to the generator. Transfer load back to electric utility when service is
restored.
Properly install and ground this
equipment according to its Owner’s
Manual and national, state, and local
codes.
Install correct switch (customer-supplied).
Switch rating must be same as or greater
than the branch overcurrent protection.
Customer-supplied
equipment is required if generator will supply standby
power during emergencies or power outages.
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
3 Fused Disconnect Switch
Install correct switch (customer-supplied) if
required by electrical code.
4 Welding Generator Output
Generator output voltage and wiring must be
consistent with regular (utility) system voltage and wiring.
Connect generator with temporary or permanent wiring suitable for the installation.
Turn off or unplug all equipment connected to
generator before starting or stopping engine.
When starting or stopping, the engine has
low speed which causes low voltage and
frequency.
5 Essential Loads
Generator output may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
requirements, connect only essential loads
(pumps, freezers, heaters, etc. − See Section 11-4).
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-492 Page 52
11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
6
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-492 Page 53
SECTION 12 − PARTS LIST
Hardware is common and
not available unless listed.
16
17
15
14
13
5
6
9
11
12
10
18
8
7
3
2
4
1
19
20
21
22
24
23
27
25
26
28
29
104
103 − Figure 12-3
98
102
101
99
97
100
96
94
94
95
90
93 − Figure 12-2
92
91
Figure 12-1. Main Assembly
OM-492 Page 54
43
44
45
42
41
40
39
54
33
46
38
37
15
36
35
34
47
48
49
31
30 − Figure 12-4
51
32
55
53
52
50
56
67
57
63
62
58
59
60
61
65
70
66
64
85
87
71
68
69
78
86
72
84
73
83
74
75
82
76
77
79
81
80
89
88
802 324-H
OM-492 Page 55
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
. . 1 . . . . . . . . . . . . +198 157
. . 1 . . . . . . . . . . ♦+198 873
. . 2 . . . . . . . . . . . . +198 155
. . 2 . . . . . . . . . . +♦198 871
. . . . . . . . . . . . . . . . . ♦163163
. . . . . . . . . . . . . . . . . ♦163175
. . . . . . . . . . . . . . . . . ♦163167
. . . . . . . . . . . . . . . . . ♦163174
. . 3 . . . . . . . . . . . . . 200 795
. . 4 . . . . . . . . . . . . . 107 990
. . 5 . . . . . . . . . . . . . 198 159
. . 6 . . . . . . . . . . . . . 200 366
. . 7 . . . . . . . . . . . . . 193 411
. . 8 . . . . . . . . . . . . . 198 156
. . 8 . . . . . . . . . . . ♦198 872
. . 9 . . . . . . . . . . . . . 198 525
. . 10 . . . . . . . . . . . +198 164
. . 10 . . . . . . . . . +♦198 878
. . 11 . . . . . . . . . . . . 194 320
. . 12 . . . . . . . . . . . . 194 295
. . 13 . . . . . . . . . . . . 198 162
. . 13 . . . . . . . . . . ♦198 875
. . 14 . . . . . . . . . . . . 200 448
. . 15 . . . . . . . . . . . . 109 591
. . 16 . . . . . . . . . . . . 201 882
. . 17 . . . . . . . . . . . . 198 153
. . 18 . . . . . . . . . . . . 176 230
. . 19 . . . . . . . . . . . . 198 154
. . 19 . . . . . . . . . . ♦198 870
. . 20 . . . . . . . . . . . . 209 344
. . 21 . . . . . . . . . . . . 090 281
. . 22 . . . . . . . . . . . . 168 385
. . 23 . . . . . . . . . . . . 198 054
. . 24 . . CR2 . . . . 155 309
. . 25 . . . . . . . . . . . . 193 414
. . 26 . . . . . . . . . . . . 172 296
. . 27 . . . . . . . . . . . . 192 239
. . 28 . . . . . . . . . . . . 206 795
. . 29 . . . . . . . . . . . . 197 265
. . 30 . . . . . . . . . Figure 12-4
. . 31 . . . . . . . . . . . . 193 624
. . 32 . . . S2 . . . . *197 145
. . . . . . . . . . . . . . . . . . 114 923
. . 33 . . . . . . . . . . . . 200 653
. . 34 . . . S3 . . . . . 205 800
. . 35 . . . . . . . . . . . . 192 517
. . 36 . . . . . . . . . . . . 192 194
. . 37 . . . . . . . . . . . . 191 693
. . 38 . . . . . . . . . . . +202 243
. . 39 . . . . . . . . . . . . 191 341
. . 40 . . . . . . . . . . . . 198 186
. . 41 . . . . . . . . . . . . 197 822
. . 42 . . . . . . . . . . . . 194 578
. . 43 . . . . . . . . . . . . 198 181
. . 44 . . . . . . . . . . . . 191 626
. . 45 . . . . . . . . . . . . 192 195
. . 46 . . . . . . . . . . . . 182 092
. . 47 . . . . . . . . . . . . 201 528
. . 48 . . . . . . . . . . . . 198 187
. . 49 . . . . . . . . . . . . 198 185
. . 50 . . . . . . . . . . . . 191 342
OM-492 Page 56
. . PANEL, generator left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PANEL, generator left stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . COVER, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . COVER, generator stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SCREW, 250−20x .50 Hex Hd−pln Stainless Pln T18−8 302−305 . . . . . . . . 37
. . SCREW, 250−20x .75 Hex Hd−pln Stainless Pln T18−8 302−305 . . . . . As Rqd.
. . WASHER, Lock .254idx0.489odx.062t Stainless Split.250 . . . . . . . . . . . . . . 37
. . WASHER, Flat .281idx0.625odx.050t Stainless . . . . . . . . . . . . . . . . . . . . . . . 37
. . LABEL, warning general precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRAY, fuel spill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . EDGE TRIM, style 70−p−11 nitrile rubber x roll . . . . . . . . . . . . . . . . . . . . . . . 2 ft
. . BRACE, hood access rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, access stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . HOOD, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOOD, access stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LATCH, door access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . LABEL, engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PLENUM, radiator cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PLENUM, radiator cover stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning steam and hot coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . CLAMP, muffler 1.750dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . PIPE, exhaust elbow 1.654 ID stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, hot exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, access removable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, access removable stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SEAL, lifting eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, caution do not use ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . UPRIGHT, base center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONTACTOR, solenoid 12VDC continuous 400 A . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, mtg gas spring front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BALL GAS SPRING, stud .39dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . SPRING, pressure gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . BRACKET, mtg air cleaner and stop door access . . . . . . . . . . . . . . . . . . . . . 1
. . GENERATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . ENGINE, Kubota dsl elec (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . SWITCH, oil pressure 7 psi no screw terminal (included w/engine) . . . . . 1
. . BOOT, insulator term post red (for starter and alternator terminals) . . . . . . 2
. . HEATER, block engine 120v 400w kabota 905 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SWITCH, thermo temp 230deg ±5deg F NO . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . GASKET, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PIPE, exhaust flexible inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . GUARD, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SHROUD, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOSE, radiator outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, mtg radiator LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RADIATOR, w/14# cap 3 row core 1.125 inlet/outlet . . . . . . . . . . . . . . . . . . . 1
. . BAFFLE, air foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RADIATOR ARCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BUMPER, door access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . PIPE, exhaust outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . MUFFLER, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, mtg radiator RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BAFFLE, lower radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOSE, radiator inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . 51 . . . . . . . . . . . . 202 198
. . 52 . . . . . . . . . . . *192 744
. . 53 . . . . . . . . . . . . 187 462
. . . . . . . . . . . . . . . . . . 208 124
. . . . . . . . . . . . . . . . . . 192 934
. . 54 . . . . . . . . . . . . 197 146
. . 55 . . . . . . . . . . . *066 113
. . 56 . . . . . . . . . . . *196 428
. . 57 . . . . . . . . . . . . 192 475
. . 58 . . . . . . . . . . . . 192 476
. . 59 . . . . . . . . . . . . 118 829
. . 60 . . . . . . . . . . . . 194 127
. . 61 . . . . . . . . . . . . 145 675
. . 62 . . . . . . . . . . . . 192 196
. . 63 . . . . . . . . . . . . 192 663
. . 64 . . . . . . . . . . . . 047 234
. . 65 . . . . . . . . . . . . 047 235
. . 66 . . . . . . . . . . . . 203 897
. . 67 . . . . . . . . . . . . 165 271
. . 68 . . . . . . . . . . . . 209 329
. . 69 . . . . . . . . . . . . 197 256
. . 70 . . . . . . . . . . . . 193 026
. . 71 . . . . . . . . . . . . 192 188
. . . . . . . . . . . . . . . . . *187 441
. . . . . . . . . . . . . . . . ♦202 102
. . 72 . . . . . . . . . . . . 197 227
. . 73 . . . . . . . . . . . . 032 453
. . 74 . . . . . . . . . . . . 204 875
. . 75 . . . . . . . . . . . . 146 237
. . 76 . . . . . . . . . . . . 494 604
. . 77 . . . . . . . . . . . . 182 276
. . 78 . . . . . . . . . . . . 110 465
. . . . . . . . . . . . . . . . . . 108 081
. . 79 . . . . . . . . . . . . . 097829
. . 80 . . . . . . . . . . . . 200 407
. . 81 . . . . . . . . . . . . 198 168
. . 82 . . . . . . . . . . . . 198 180
. . 83 . . . . . . . . . . . . 124 253
. . 84 . . . . . . . . . . . . 198 510
. . 85 . . . . . . . . . . . . 198 511
. . 86 . . . . . . . . . . . . 190 198
. . 87 . . . . . . . . . . . . 198 512
. . 88 . . . . . . . . . . . . 189 908
. . 89 . . . . . . . . . . . . 181 572
. . 90 . . . . . . . . . . . . 197 930
. . 91 . . . . . . . . . . . . 197 835
. . 92 . . . . . . . . . . . . 192 477
. . 93 . . . . . . . . . Figure 12-2
. . 94 . . . . . . . . . . . . 198 167
. . 95 . . . . . . . . . . . . 190 861
. . BASE, fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FILTER, fuel spin-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BOTTLE, overflow w/cap and hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . CAP, w/gasket overflow bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, mtg coolant recovery tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FAN, engine 330mm pusher kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FILTER, fuel inline .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SUPPORT, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . MOUNT, engine vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . SCREW, shld stl sch .312-18 x .500 x .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LINKAGE, throttle solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . NUT, .312-18 x .50 hex .37h stl pld deformed . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SOLENOID, 12VDC 46A push/hold (throttle) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BOLT, banjo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . WASHER, seal oil copper .879 ID x 1.059 OD . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOSE, oil w/fittings 22.500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . VALVE, oil drain 3/8-18 NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . INDICATOR, restriction air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOSE, elbow air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BAND, mtg air cleaner case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . AIR CLEANER, intake 90deg outlet 4.25 in dia . . . . . . . . . . . . . . . . . . . . . . . . 1
. . ELEMENT, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . ELEMENT, air cleaner safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOSE, elbow air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, bat neg 24.375 No. 2 awg w/clamp and .375 rng . . . . . . . . . . . . . . 1
. . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BATTERY, stor 12V 535crk 90rsv gp 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BOLT, j stl .250−20 x 8.000 pld w/nuts&washers . . . . . . . . . . . . . . . . . . . . . . 2
. . CABLE, bat pos 28.000 No. 1 awg w/clamp and .406 lug . . . . . . . . . . . . . . . 1
. . TUBING, corrugated plastic slit .500 dia xcoil . . . . . . . . . . . . . . . . . . . . . . . . 2.1 ft
. . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . BOLT, J Stl .250−20 X 2.750 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STRAP, Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SUPPORT, Fuel Tank/Weld Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TANK, Fuel 13.1 Gal (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . BUSHING, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . FTG, Stand Pipe Hose .3125 X24.570lg 90 Deg Zinc . . . . . . . . . . . . . . . . 1
. . . . FTG, Stand Pipe Hose .1875x24.570lg 90 Deg Zinc . . . . . . . . . . . . . . . . . 1
. . . . CAP, Tank Screw−on 3.500 In W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . SENDER, Fuel Gauge 22.500 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . VALVE, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . BUSHING, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . MOUNT, engine vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FRONT PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SUPPORT, inverter chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . LABEL, electric shock and moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-492 Page 57
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . . 213 226 . . HARNESS, wiring ignition (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 96 CR1, CR2 . . 173 069 . . . . RELAY, encl 12VDC SPDT 30A/20A 5 pin flange mtg . . . . . . . . . . . . . . . . 2
. . 97 . . . . . . . . . . . . 197 147 . . . . BLOCK, term 5-4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 98 . . . D3 . . . . . 135 184 . . . . DIODE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 99 . . . . . . . . . . . . 191 735 . . . . STRIP, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG26 . . . 135 275 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug (service kit) . . . . . . . . . . . 1
. . . . . . . . PLG5 . . . . 166 680 . . . . CONNECTOR, rect univ 084 12P/S 3 row plug (service kit) . . . . . . . . . . . 1
. . . . . . . . PLG8 . . . . 177 859 . . . . CONNECTOR, body 5 terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG34 . . . 153 501 . . . . CONNECTOR, rect univ 039 6P/S 3 row plug (service kit) . . . . . . . . . . . . 2
. . . . . . . . . S6 . . . . . 021 467 . . . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 187 654 . . . . SEAL, wire univ 12p/s 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 187 655 . . . . SEAL, wire univ 15p/s 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 208 871 . . HARNESS, wiring engine compartment (consisting of) . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC5 . . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG38 . . . 192 170 . . . . CONNECTOR, rect 250 2skt 1 row plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 192 169 . . . . CONNECTOR, rect 250 1skt 1 row plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG36 . . . 192 171 . . . . CONNECTOR, rect 250 3skt 1 row plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG37 . . . 192 168 . . . . CONNECTOR, rect 250 1 pin 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG39 . . . 092 670 . . . . CONNECTOR, rect univ 084 3P/S 1 row plug . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 192 167 . . . . SEAL, wire univ 3P/S 1 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 100 . . CB7 . . . . 147 658 . . . . CIRCUIT BREAKER, man rest 1P 30A 250VAC screw (see Figure 12-1) 1
. 101 . . CB8 . . . . 115 427 . . . . CIRCUIT BREAKER, man reset 1P 25A 250VAC frict (see Figure 12-1) 1
. 102 . . CB10 . . . . 139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict (see Figure 12-1) 1
. . . . . . . . . . . . . . . . . . 187 654 . . . . SEAL, wire univ 12p/s 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin (for CR3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 103 . . . . . . . . . Figure 12-3 . . INVERTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 104 . . . . . . . . . . . . 198 158 . . PANEL, generator right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 104 . . . . . . . . . . ♦198 874 . . PANEL, generator right stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 194 126 . . KIT, foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+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-492 Page 58
Hardware is common and
not available unless listed.
25
30
38
29
6
31
12
32
34
26
27
24
33
23
28
21
20
35
19
22
18
36
37
8
6
14
13
16
15
17
40
1
12
5
11
41
8
39
10
7
4
3
9
2
802 327-C
Item
No.
Dia.
Mkgs.
Part
No.
Figure 12-2. Front Panel
Description
Quantity
Figure 12-2. Front Panel (Figure 12-1, Item 93)
. . 1 . . . . . . . . . . . . . 198 049 . .
. . 2 . . . . . . . . . . . . +191 737 . .
. . 3 . . . . . . . . . . . . . 170 391 . .
. . 4 RC14, PC6 . 224 951 . .
. . . . . . . PLG13 . . . 115 091 . .
. . 5 . CB5,CB6 . . 083 432 . .
. . 6 . . 2T, 3T . . . 172 661 . .
. . 7 . . . . . . . . . . . . . 212 480 . .
. . 8 . . . . . . . . . . . . . 206 795 . .
. . 9 . . . . . . . . . . . . . 601 836 . .
. . 10 . . . . . . . . . . . . 039 046 . .
. . 11 . . PC10 . . . . 148 608 . .
. . 12 . . . . . . . . . . . . 134 201 . .
. . 13 . . . . . . . . . . . . . . . . . . . . . . .
. . 14 . . . . . . . . . . . . . . . . . . . . . . .
. . 15 . . . . . . . . . . . . 039 047 . .
. . 16 . . . . . . . . . . . . 083 030 . .
. . 17 . . . . . . . . . . . . 213 456 . .
. . 18 . . . . . . . . . . . . 209 056 . .
. . 19 . . . . . . . . . . . . 203 016 . .
. . 20 . . . . . . . . . . . . 119 014 . .
. . 21 . . . . . . . . . . . . 021 385 . .
UPRIGHT, base front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONN, circ ms protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, connector/receptacle . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR, rect mini 045 10skt 2 row plug (service kit) . . . . . . . . . . . . .
CIRCUIT BREAKER, man reset 1P 10A 250VAC frict . . . . . . . . . . . . . . . . . .
BLOCK, stud connection 6 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, 250-20 .50hex .19H brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSEMBLY, filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND−OFF SUPPORT, pc card .312/.375w/post&lock .43 . . . . . . . . . . . .
PLATE, lower (order by model & serial number) . . . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE, upper (order by model & serial number) . . . . . . . . . . . . . . . . .
TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STUD, brs .250-20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER, receptacle duplex dual gfci weather proof . . . . . . . . . . . . . . . . . . . .
COVER, receptacle w/ gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOOT, circuit breaker 2 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
2
1
4
8
1
1
6
1
1
1
2
1
2
1
1
1
OM-492 Page 59
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-2. Front Panel (Continued)
. . 22 . . . . . . . . . . . . 192 265 . . GAUGE, fuel elec switch w/o switchgage sensor . . . . . . . . . . . . . . . . . . . . . . 1
. . 23 . . . . . . . . . . . . 145 247 . . METER, hour 12−24vdc 1.25 x 2.12 rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 PL1, PL2, PL3 . 206 879 . . LIGHT, ind amber lens 12v snap−in mtg .500 mtg hol . . . . . . . . . . . . . . . . . . 1
. . 25 . . CT2 . . . . 192 237 . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 26 . . . S4 . . . . . 108 024 . . SWITCH, tgl DPST mc 15a 125V ac friction . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . S1 . . . . . 176 606 . . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . PC3 . . . . 225 974 . . CIRCUIT CARD ASSEMBLY, front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 210 844 . . SHIELD, pcb protective anti static 6.338x11.000 . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . RC1 . . . . 182 954 . . RECEPTACLE, str 3p4w 50a 125/250V (single-phase) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . ♦119 172 . . PLUG, str grd 3p4w 50a 125/250v *14−50p (for RC1) . . . . . . . . . . . . . . . . . . 1
. . 30 . . CB3 . . . . 217 858 . . CRICUIT BREAKER, man reset 2p, 50a 240 V ac Screw 90 . . . . . . . . . . . . 1
. . 31 RC2, RC3 . . 214 918 . . RECEPTACLE, str dx grd 2p3w 20a 125v *5−20r . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . GFCI-1, 2 ♦151 981 . . RECEPTACLE, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . 2
. . 32 CB2,CB3 . . 093 996 . . CIRCUIT BREAKER, man reset 1P 20a 250Vac frict . . . . . . . . . . . . . . . . . . 2
. . 33 . . RC4 . . . . 007 469 . . RECEPTACLE, twlk grd 3P4W 30A 250V (3-phase) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦007 470 . . PLUG, tw lk grd 3p4w 30a 250v *l15−30p (For RC4) . . . . . . . . . . . . . . . . . . . 1
. . 34 . . CB4 . . . . 192 565 . . CIRCUIT BREAKER, man reset 3p 30a 250VAC . . . . . . . . . . . . . . . . . . . . . . 1
. . 35 . . . . . . . . . . . . 203 017 . . BOOT, circuit breaker 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 36 . . . . . . . . . . . . 174 991 . . KNOB, pointer 1.250dia x .250 ID w/spring clip . . . . . . . . . . . . . . . . . . . . . . . 2
. . 37 . . . . . . . . . . . . 174 992 . . KNOB, pointer .820dia x .250 ID w/spring clip . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 38 . . PC9 . . . . 181 261 . . CIRCUIT CARD ASSY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 40 . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 41 . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-492 Page 60
Hardware is common and
not available unless listed.
34
35
33
36
5
26
37
27
18
38
39
40
41
28
42
32
25
29
24
23
31
22
44
30
21
43
20
45
19
15
46
18
47
17
16
10
9
5
8
4
7
6
3
14
13
Item
No.
Dia.
Mkgs.
2
11
12
1
802 326-A
Figure 12-3. Inverter Assembly
Part
No.
Description
Quantity
Figure 12-3. Inverter Assembly (Figure 12-1, Item 103)
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
1 . . . PC2 . . . . 196 148
2 . C3,C4,C5 . . 192 935
3 . . . . C1 . . . . . 186 015
4 . . . . . . . . . . . . . 025 248
5 . . . . . . . . . . . . . 179 276
6 . . . . . . . . . . . . . 175 140
7 . . . . . . . . . . . . . 181 197
8 . . . L3,L4 . . . . 175 482
9 . . . . . . . . . . . . . 109 056
10 . . . . . . . . . . . . 185 731
11 . . . . . . . . . . . . 189 755
12 . . . . . . . . . . . . 191 568
13 . . . . . . . . . . . . 200 649
14 . . . . . . . . . . . . 170 647
15 . . . . . . . . . . . . 175 084
16 . . SR1 . . . . 179 629
17 PM1,PM2 . . 180 110
18 RT1,RT2 . . 173 632
19 . . . . . . . . . . . . 173 631
20 . . . . . . . . . . . . 175 192
21 . . . . . . . . . . . . 175 255
22 . . . . . . . . . . . +183 551
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..
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..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
CIRCUIT CARD ASSEMBLY, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, elctlt 2700uf 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, polyp film .34uf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND-OFF, insul .250-20 x 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap-in nyl 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET, DI/DT rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL, DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORE, ferrite E 2.164 lg x 1.09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOOT, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap-in 1.312 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR, fan 24VDC 3000RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, diode power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC 30K ohm at 25D C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3
1
2
1
1
1
2
2
1
1
2
1
2
1
1
2
2
1
1
1
1
OM-492 Page 61
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-3. Inverter Assembly (Continued)
. . 23 . . . . . . . . . . . . 181 853
. . 24 . . HD1 . . . . 189 567
. . 25 . D1,D2 . . . 179 630
. . 26 R1,C6,C7 . . 175 194
. . 27 . . . . . . . . . . . . 185 835
. . 28 . . . T1 . . . . . 173 811
. . 29 . . . L1 . . . . . 173 563
. . 30 . . . Z1 . . . . . 189 525
. . 31 . . . . . . . . . . . . 189 420
. . 32 . . PC1 . . . . 212 691
. . 33 . . . . . . . . . . . +213 412
. . 34 . . . . . . . . . . . . 190 861
. . 35 . . . . . . . . . . . . 200 590
. . 36 . . . T2 . . . . . 189 481
. . 37 . . . . . . . . . . . . 172 731
. . 38 . . . F1 . . . . . 169 296
. . 39 . . . . . . . . . . . . 189 422
. . 40 . . SR2 . . . . 035 704
. . 41 . . . . . . . . . . . . 115 440
. . 42 . . . . . . . . . . . . 200 651
. . 43 . . PC8 . . . . 213 231
. . 44 . . PC7 . . . . 203 130
. . . . . . . . . F1 . . . . . . 027660
. . 45 . . . . . . . . . . . . 153 403
. . 46 . . . . . . . . . . . . 177 547
. . 47 . . CT1 . . . . 175 199
. . . . . . . . . . . . . . . . . . 213 410
. . . . . . . . RC26 . . . . 147 663
. . . . . . . . RC25 . . . . 116 045
. . . PLG24, PLG44 115 094
. . . . RC10, PLG31 168 071
. . . . . . . . PLG2 . . . . 115 091
. . . . . . . PLG23 . . . 130 203
. . . . . . . . RC24 . . . . 047 483
. . . . . . . PLG50 . . . 136 810
. . . . . . . PLG43 . . . 115 093
. . . . . . . PLG21 . . . 115 092
. . . . . . . PLG22 . . . 131 204
. . . . . . . . PLG9 . . . . 183 046
. . INSULATOR, screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSDUCER, current 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT, diode ultra-fast recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, HF 230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STABILIZER, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg capacitor/PC board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSEMBLY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WRAPPER, inverter chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, electric shock and moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, ribbon access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, control 300VA 230VAC pri . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, fuse mintr .250 x 1.250 clip anti−pivot . . . . . . . . . . . . . . . . . . . . . .
. . FUSE, mintr gl 25. amp 125 volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg transformer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, integ bridge 40. amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, No. 6-32 x .687 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSEMBLY, voltage regulator . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, gen power (includes) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FUSE, Mintr Cer 20. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, snap-in nyl .750 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, snap-in nyl ct-mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HARNESS, wiring unit (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect univ 084 15 p/s 3 row rectp lkg (service kit) . . . . . . .
. . . . CONNECTOR, rect univ 084 6p/s 3 row rcpt lkg (service kit) . . . . . . . . . .
. . . . CONNECTOR, rect mini 045 4skt 2 row plug (service kit) . . . . . . . . . . . . .
. . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt (service kit) . . . . . . . . . . . .
. . . . CONNECTOR, rect mini 045 10skt 2 row plug (service kit) . . . . . . . . . . . .
. . . . CONNECTOR, rect mini 045 12 skt 2 row plug (service kit) . . . . . . . . . . .
. . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt (service kit) . . . . . . . . . . .
. . . . CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg (service kit) . . . .
. . . . CONNECTOR, rect mini 045 6skit 2row plg cable lkg (service kit) . . . . . .
. . . . CONNECTOR, rect mini 045 8skt 2row plug cable lkg (service kit) . . . . .
. . . . CONNECTOR, rect mini 045 3skt 1row plug cable lkg (service kit) . . . . .
. . . . CABLE, LEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*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-492 Page 62
Hardware is common and
not available unless listed.
8
7
6
3
5
4
1
9
2
10
11
802 338-A
Figure 12-4. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-4. Generator Assembly (Figure 12-1, Item 30)
. . 1 . . . . . . . . . . . . . 217 046 . . ENDBELL (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . 216 532 . . . . RING, tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . 213 388 . . ROTOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . 181 143 . . . . BEARING, ball rdl sgl row .984 x 2.047 x .591 . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . 192 600 . . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . +212 957 . . STATOR, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . 159 918 . . BAFFLE, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . 193 515 . . ADAPTER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 10 . . . . . . . . . . . . 170 861 . . STUD, stl .375-16 x 17.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 11 . . . . . . . . . . . . 205 725 . . BRUSHHOLDER ASSY, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*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-492 Page 63
Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue® for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
miller_warr 1/05
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
www.MillerWelds.com
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2005 Miller Electric Mfg. Co.
1/05
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