Miller | LE083195 | Owner Manual | Miller PRO 300 CAT User manual

Miller PRO 300 CAT User manual
OM-4422
215 177B
February 2004
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
PRO 300
(CAT-Powered)
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 7/03
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Manufacturer’s Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Welding Generator (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Lift-ArcE Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. 120 Volt And 240 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
3
3
4
4
4
5
5
5
6
7
7
8
8
9
9
13
14
15
15
15
16
17
17
18
19
19
20
21
22
23
24
25
25
26
28
28
29
30
31
32
33
33
TABLE OF CONTENTS
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Caterpillar Customer Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Adjusting Engine Speed On Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Adjusting Engine Speed On Models With Automatic Idle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
34
34
35
36
37
38
38
39
40
41
42
43
44
48
50
50
51
52
53
60
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_8/03
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.
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.
Marks a special safety message.
Means “Note”; not safety related.
1-2. Arc Welding Hazards
Use only well-maintained equipment. Repair or replace damaged parts at
once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
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.
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.
SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine.
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!
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
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.
Stop engine on inverter and discharge input capacitors according to
instructions in Maintenance Section before touching any parts.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove welding
fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instructions for metals, consumables, coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while wearing an 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 if necessary, 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 a welding helmet fitted with a proper shade of filter to protect your face
and eyes from arc rays and sparks when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from flash and glare;
warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (wool
and leather) and foot protection.
Return To Table Of Contents
OM-4422 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.
NOISE can damage hearing.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not
possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause
fire on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes, unless
they are properly prepared according to AWS F4.1 (see Safety Standards).
Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and
causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at contact tip
when not in use.
Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches, from your
person before doing any welding.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
work and have a fire watcher and extinguisher nearby.
Noise from some processes or equipment can damage
hearing.
Wear approved ear protection if noise level is high.
MAGNETIC FIELDS can affect pacemakers.
FLYING METAL can injure eyes.
Allow cooling period before maintaining.
Wear protective gloves and clothing when working on
a hot engine.
Do not touch hot engine parts or just-welded parts
bare-handed.
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.
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, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary support or
cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in
good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in use or
connected for use.
Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
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-4422 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 guards or covers for maintenance
and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect negative (−)
battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving parts.
Reinstall panels or guards and close doors when servicing is finished
and before starting engine.
Before working on generator, remove spark plugs or injectors to keep
engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator components.
Return To Table Of Contents
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.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Release air pressure from tools and system before
servicing, adding or changing attachments, or opening compressor oil drain or oil fill cap.
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.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running gear, gas
cylinders, trailer, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or stopping engine.
Do not let low voltage and frequency caused by low
engine speed damage electric motors.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before starting
to weld again.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where
applicable.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to store,
move, or ship PC boards.
FLYING SPARKS can cause injury.
TILTING OF TRAILER can cause injury.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with proper
guards in a safe location wearing proper face, hand,
and body protection.
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.
Return To Table Of Contents
OM-4422 Page 3
READ INSTRUCTIONS.
ARC WELDING can cause interference.
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.
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.
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
Have only qualified persons familiar with electronic
equipment perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at
once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep spark
gaps at correct setting, and use grounding and shielding to minimize the
possibility of interference.
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.
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 American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www.
sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
in Toronto 416-747-4044, website: www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices—phone for Region 5, Chicago, is
312-353-2220, website: www.osha.gov).
1-8. 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-4422 Page 4
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
Return To Table Of Contents
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 8/03
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 2-6 . Veuillez lire et respecter toutes
ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de
mise à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé − remplacer le cordon immédiatement s’il est
endommagé − un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
une électrode provenant d’une autre machine.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec
la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès
que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact avec
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la
terre présentent un danger.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas
de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel
avec la pièce ou la terre.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
Des précautions de sécurité supplémentaires sont requises dans des envi-
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des
blessures ou des accidents mortels. S’assurer que l’air de respiration ne
présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et
tous les métaux renfermant ces éléments peuvent dégager des fumées
toxiques en cas de soudage.
ronnements à risque comme: les endroits humides ou lorsque l’on porte
des vêtements mouillés; sur des structures métalliques au sol, grillages et
échafaudages; dans des positions assises, à genoux et allongées; ou
quand il y a un risque important de contact accidentel avec la pièce ou le
sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence:
1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un
poste à souder manuel (électrode enrobée) DC, 3) un poste à souder manuel AC avec tension à vide réduite. Dans la plupart des cas, un poste
courant continu de type CV est recommandé. Et, ne pas travailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation,
à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre
du sectionneur ou que la fiche du cordon est raccordée à une prise
correctement mise à la terre.
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des composants.
Revenez à la table des matières
OM-4422 Page 5
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B
pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets et
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de
l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
Porter des vêtements de protection constitué dans une matière durable, résistant au feu (laine ou cuir) et une protection des pieds.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
Prévoir une période de refroidissement avant d’effectuer des travaux d’entretien.
Porter des gants et des vêtements de protection pour
travailler sur un moteur chaud.
Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
récemment soudées.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
LE SOUDAGE peut provoquer un incendie ou une explosion.
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Le soudage effectué sur des conteneurs fermés tels que
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles peuvent être projetées de
l’arc de soudure. La projection d’étincelles, des pièces chaudes et des
équipements chauds peut provoquer des incendies et des brûlures. Le contact
accidentel de l’électrode avec des objets métalliques peut provoquer des
étincelles, une explosion, un surchauffement ou un incendie. Avant de
commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
substances inflammables.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Déplacer toutes les substances inflammables à une distance de 10,7 m de
l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec
des protections homologués.
Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des
ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés
correctement conformément à AWS F4.1 (voir les normes de sécurité).
Brancher le câble sur la pièce le plus près possible de la zone de soudage
pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et
d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porte-électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des gants
en cuir, une chemise en matériau lourd, des pantalons sans revers, des
chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches telles
qu’un allumeur au butane ou des allumettes.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec
précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou
dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords convenables pour cette application spécifique; les maintenir ainsi
que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
les équipements associés et les publication P-1 CGA énumérées dans les
normes de sécurité.
2-3. Dangers existant en relation avec le moteur
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
OM-4422 Page 6
Revenez à la table des matières
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.
Toujours porter une protection faciale, des gants en
caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher les câbles de
batterie.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier
lieu.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,
débrancher le câble négatif (−) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles.
Remettre en place les panneaux ou les dipositifs de protection et fermer les
portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en
route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le
générateur.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Toujours vérifier le niveau de liquide de refroidissement dans le vase d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement
dans la section maintenance du manuel du moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant :
Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas approcher les mains des ventilateurs, courroies et autres pièces en mouvement.
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
Arrêter le moteur avant d’installer ou brancher l’appareil.
Demander seulement à un personnel qualifié d’enlever les dispositifs de
sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.
Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces inflammables.
Tenir à distance les produits inflammables de
l’échappement.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé −
voir codes en vigueur.
2-4. Dangers liés à l’air comprimé
RESPIRER L’AIR COMPRIMÉ peut provoquer des blessures graves ou causer
la mort.
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un incendie ou une explosion.
Ne pas utiliser l’air comprimé pour respirer.
Utiliser l’air comprimé seulement pour le coupage, gougeage et les outils pneumatiques.
Ne pas couper ou gouger à proximité de produits
inflammables.
Surveillez et garder un extincteur à proximité.
L’AIR COMPRIMÉ peut provoquer
des blessures.
DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.
Porter des lunettes de sécurité approuvées.
Ne pas diriger le jet d’air vers d’autres ou soi−
même.
Ne pas toucher le compresseur ou d’autres éléments du circuit air comprimé chauds.
Laisser l’ensemble se refroidir avant de toucher
ou d’effectuer la maintenance.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provoquer des blessures.
LIRE LES INSTRUCTIONS.
Relâcher la pression d’air de l’outillage ou du système avant d’effectuer la maintenance, avant de
changer ou de rajouter des éléments ou avant
d’ouvrir la purge ou le bouchon de remplissage
d’huile.
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
Arrêter le moteur et relâcher la pression avant
d’effectuer la maintenance.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la
maintenance
LA CHUTE DE L’APPAREIL peut
blesser.
Utiliser l’anneau de levage uniquement pour soulever
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.
Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
Revenez à la table des matières
OM-4422 Page 7
LE SURCHAUFFEMENT peut endommager le moteur électrique.
LIRE LES INSTRUCTIONS.
Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur.
Ne pas laisser tourner le moteur trop lentement sous
risque d’endommager le moteur électrique à cause
d’une tension et d’une fréquence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a
lieu.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Établir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements
de radio−navigation et de communication, les
services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées avec des
équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des sources
de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et et un blindage pour réduire les interférences
éventuelles.
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
Porter un écran facial pour protéger le visage et les
yeux.
Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque
l’on porte l’équipement homologué de protection du visage, des mains et
du corps.
Les étincelles risquent de causer un incendie − éloigner toute substance
inflammable.
Utiliser les supports de la remorque ou des blocs
pour soutenir le poids.
Installer convenablement le poste sur la remorque
comme indiqué dans le manuel s’y rapportant.
Utiliser seulement les pièces de rechange d’origine.
Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du
moteur/compresseur (si applicable).
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible
électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que
le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-6. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping, norme American Welding Society AWS F4.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101
(téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de
la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web :
www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard Rexdale,
Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site
Web : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,
norme NFPA 51B, de la National Fire Protection Association, P.O. Box
9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
770−3000, site Web : www.nfpa.org et www.sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
Web : www.osha.gov).
2-7. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques
basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent préoccupants.
Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité de spécialistes du
National Research Council a conclu : « L’accumulation de preuves n’a pas
démontré que l’exposition aux champs magnétiques et aux champs électriques à haute fréquence constitue un risque pour la santé humaine ».
Toutefois, les études et l’examen des preuves se poursuivent. En attendant
les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs électromagnétiques pendant le soudage ou le
coupage.
OM-4422 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
Revenez à la table des matières
SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions
2
1
3
4
5
1
6
10
+ −
1
1
4
4
11
+
+
−
−
3
3
2
2
7
+
+
−
−
S-176 108
8
9
12
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Do not smoke and keep
matches and flames away from
battery.
3 Sparks can cause battery
gases to explode. Battery
explosion can blind and injure.
Wear a face shield.
4 Battery acid can burn skin. Do
not spill acid.
5 Read Owner’s Manual.
6 Wear rubber gloves.
7 Dead battery
8 Engine block
9 Fully charged battery
10 Do not connect last negative
cable to dead battery − connect
instead to engine block.
11 Jumper cables − observe
polarity and make connections
in numbered sequence shown.
12 Once dead battery is charged,
disconnect cables in sequence
3/96
shown.
1
1
2
2
3/96
S-176 106
1
2
1
2
3
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
injury. Keep away from moving
parts.
4
3
4
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Ether will damage engine. Do
not use ether as a starting aid.
Read Owner’s Manual.
Use glow plugs for 10−25
seconds to aid starting in cold
weather.
6/02
Return To Table Of Contents
OM-4422 Page 9
1
1
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Hot muffler and exhaust pipes
can cause severe burns. Do
not touch hot muffler or pipes.
2
S-176 230
3/96
1
2
3
4
5
6
3/96
1
1
2
3
4
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling equipment can cause
serious injury and damage.
Use lifting eye to lift or move
unit
only.
Use
proper
equipment when lifting.
Do not use lifting eye to lift and
support unit and trailer or other
heavy devices or accessories.
S-176 104
2
OM-4422 Page 10
3
Return To Table Of Contents
4
3/96
1
1
2
2
3
4
5
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Fire hazard from leaking
engine fuel. Fire can result from
welding
on
base
at
non-designated areas causing
a possible fuel leak.
Fuel tank is located inside
base.
Do not weld on base of unit.
Weld only on supplied brackets
or bolt unit down.
5
3
4
1
1
2
3
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
injury. Keep away from moving
parts.
3
Return To Table Of Contents
OM-4422 Page 11
S-177 571
1
+
2
1
2
3
+
3
4
DIESEL
5
4
6
5
7
0 − 50 h Std.
200A
Remove unit from shipping
crate. Remove Owner’s
Manual from unit. Follow
instructions to install muffler.
Read Owner’s Manual. Read
labels on unit.
Use Diesel Fuel only, and fill
fuel tank. Leave room for
expansion.
Warning! Watch Out! There
are possible hazards as
shown by the symbols. Read
Owner’s Manual. Follow
instructions to activate
battery.
Check oil level. Add oil if
necessary.
During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
After the first 50 hours of
operation, change the oil and
oil filter.
0 − 200A
50 h Std.
API CD-MIL L 2104D,
CD/SE, CD/SF
3/96
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4422 Page 12
Return To Table Of Contents
3-2. Manufacturer’s Rating Label
Ref. 216 347-B
Return To Table Of Contents
OM-4422 Page 13
3-3. Symbols And Definitions
NOTE
Some symbols are found only on CE products.
Stop Engine
Fast (Run, Weld/
Power)
Slow (Idle)
Start Engine
Starting Aid
(Preheat)
Battery (Engine)
Engine Oil
Pressure
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
Panel/Local
Remote
Engine
Air Temperature Or
Engine
Temperature
Output
Alternating
Current
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
TIG (GTAW)
A
Amperes
Time
3
V
h
Hours
Three Phase
Read Operator’s
Manual
Electrode
Connection
Work Connection
s
Seconds
G
3
Engine-Driven,
Three-Phase
Alternator With
Rectifier
Duty Cycle
U0
Rated No Load
Voltage (Average)
U2
Conventional
Load Voltage
n1
Rated Idle
Speed
n0
Rated No Load
Speed
I
Current
OM-4422 Page 14
Single Phase
Do Not Switch
While Welding
Circuit Breaker
X
Contactor On
1
Arc Force (Dig)
Return To Table Of Contents
Lift-Arc TIG
Hz
n
I2
Hertz
Rated Load
Speed
Rated Welding
Current
SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Welding
Mode
Weld Output
Range
Rated Welding
Output
Maximum
OpenCircuit
Voltage
Generator Power
Rating
65
Single-Phase,
10 kVA/kW, 84/42 A,
120/240 V AC,
60 Hz
Fuel
Capacity
Engine
400 A, 23 Volts DC,
40% Duty Cycle
CC/DC
300 A, 32 Volts DC
60% Duty Cycle
20 − 410 A
250 A, 30 Volts DC
100% Duty cycle
400 A, 23 Volts DC,
30% Duty Cycle
CV/DC
300 A, 29 Volts DC
60% Duty Cycle
14 − 40 V
Caterpillar 3013C
Water-Cooled,
Three-Cylinder,
22 HP Diesel Engine
11.5 gal
(43.5 L)
250 A, 26.5 Volts DC
100% Duty cycle
4-2. Dimensions, Weights, And Operating Angles
Dimensions
Height
35 in (889 mm)
(to top of exhaust)
G
26-1/4 in (667 mm)
(mtg. brackets turned in)
Do not exceed tilt angles or engine could
be damaged or unit could tip.
Width
Do not move or operate unit where it could
tip.
28-3/4 in (730 mm)
(mtg. brackets turned out)
Depth
56 in (1422 mm)
A
56 in (1422 mm)
B
54 in (1372 mm)
C
52 in in (1321 mm)
D
2 in (51 mm)
E
26 in (660 mm)
F
7/8 in (22 mm)
G
27-3/4 in (705 mm)
H
9/16 in (14 mm) Dia.
4 Holes
Weight
A
B
C
30°
20°
H
Front Panel End
D
30°
20°
F
E
No fuel: 1100 lb (499 kg)
w/ fuel: 1199 lb (544 kg)
Return To Table Of Contents
OM-4422 Page 15
4-3. Volt-Ampere Curves
DC VOLTS
A. Stick Mode
100
90
80
70
60
50
40
30
20
10
0
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
MIN
0
300
100
200
300
MAX
400
500
400
500
DC AMPERES
B. MIG Mode
100
DC VOLTS
80
60
40
20
0
0
100
200
300
DC AMPERES
C. TIG Mode
100
DC VOLTS
80
60
40
20
MIN
300
0
0
100
200
300
MAX
400
500
DC AMPERES
217 517 / 217 516 / 217 518
OM-4422 Page 16
Return To Table Of Contents
4-4. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
2.00
U.S. GAL/HR.
1.75
1.50
1.25
1.00
0.75
0.50
IDLE
0.25
0.00
0
50
100
150
200
250
300
350
400
DC WELD AMPERES AT 100% DUTY CYCLE
217 509
4-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
100% Duty Cycle At 250 Amperes
Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
1000
WELD AMPERES
800
600
500
400
CC
CV
300
250
200
150
100
10
15
20
25
30
40
50
60
80
100
% DUTY CYCLE
217 515
Return To Table Of Contents
OM-4422 Page 17
4-6. AC Generator Power Curve
The ac power curve shows the generator power in amperes available
at the 120 and 240 volt receptacles.
150 300
AC VOLTS
125 250
100 200
75 150
50 100
25
50
0
0
0
20
40
60
80
AC AMPERES IN 240 V MODE
0
40
80
120
160
AC AMPERES IN 120 V MODE
217 519
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
OM-4422 Page 18
Return To Table Of Contents
SECTION 5 − INSTALLATION
5-1. Installing Welding Generator (See Section 5-2)
Always securely fasten welding generator onto transport
vehicle or trailer and comply
with all DOT and other applicable codes.
Movement
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
If unit does not have GFCI receptacles, use GFCI-protected
extension cord.
OR
See Section 5-2 for mounting information.
Grounding:
1
Location
2
3
OR
OR
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.
Grounding
1
GND/PE
2
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
3
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.
Airflow Clearance
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
install3 11/02 − Ref. 800 652 / Ref. 800 477-A / 803 274
Return To Table Of Contents
OM-4422 Page 19
5-2. Mounting Welding Generator
Do not weld on base. Welding on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
Supporting The Unit
Do not mount unit by supporting the base only at the
four
mounting brackets.
Use cross-supports to adequately support unit and prevent damage to base.
2
Mounting Surface:
1
2
OR
Cross-Supports
Mounting Brackets (Supplied)
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brackets.
1
3
Inadequate support.
4
Do not use flexible mounts.
1/2 in Bolt And Washer
(Minimum − Not Supplied)
3/8-16 x 1 in Screws
(Supplied)
To Bolt Unit In Place:
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
1
Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
Using Mounting Brackets
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
2
Welding Unit In Place
Bolting Unit In Place
3
2
4
Tools Needed:
9/16 in
install3 5/02 − 800 652 / 200 864-A / 803 231 / 803 562
OM-4422 Page 20
Return To Table Of Contents
5-3. Installing Exhaust Pipe
Stop engine and let cool.
Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in
803 582 / Ref. 214 778-B
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Return To Table Of Contents
OM-4422 Page 21
5-4. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1
5
4
1
2
3
4
5
Eye Protection − Safety
Glasses Or Face Shield
Rubber Gloves
Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
Well
Fill each cell with electrolyte to
bottom of well (maximum).
3
Do not overfill battery cells.
Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
6
Battery Charger
Read and follow all instructions supplied with battery
charger.
2
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 amperes. Disconnect charging cables
and install battery.
When electrolyte
is low, add
only distilled water to cells to
maintain proper level.
6
5 A For 30 Minutes
Tools Needed:
OR
+
−
rubber gloves
30 A For 12 Minutes
glasses
drybatt1 1/98 − 0886
OM-4422 Page 22
Return To Table Of Contents
5-5. Connecting The Battery
Close door after connecting battery.
Tools Needed:
1/2 in
Connect Negative (−) Cable Last.
+
−
803 563 / Ref. 214 778-B / S-0756-C
Notes
Return To Table Of Contents
OM-4422 Page 23
5-6. Engine Prestart Checks
Check radiator coolant
level when fluid is low in
recovery tank.
Full
Full
Diesel
Capacity:
6 qt (5.7 L)
Coolant Recovery Tank
Hot Full
Cold Full
Full
803 563
Check all engine fluids daily.
Engine must be cold and on a level surface.
Unit is shipped with 20W break-in oil.
Automatic shutdown system stops engine if
oil pressure is too low or coolant temperature is too high.
This unit has a low oil pressure shut-
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 10.
Fuel
Do not use gasoline. Gasoline will
damage engine.
The unit is shipped with enough fuel to prevent air from entering fuel system. Add fresh
diesel fuel before starting (see engine maintenance label for fuel specifications). Leave
filler neck empty to allow room for
expansion.
OM-4422 Page 24
Do not run out of fuel or air will enter fuel system and cause starting problems. See engine manual to bleed air from fuel system.
freeze to mixture if using the unit in temperatures below −34° F (−37° C).
Oil
Keep radiator and air intake clean and free
of dirt.
After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Coolant
Check coolant level in radiator before starting unit the first time. If necessary, add coolant to radiator until coolant level is at bottom
of filler neck.
Check coolant level in recovery tank daily.
If necessary, add coolant to recovery tank
until coolant level is between Cold Full and
Hot Full levels. If recovery tank coolant level
was low, also check coolant level in radiator.
Add coolant if level is below bottom of radiator filler neck.
Unit is shipped with an engine coolant mixture of water and ethylene glycol base antifreeze rated to −34° F (−37° C). Add antiReturn To Table Of Contents
Incorrect engine temperature can
damage engine. Do not run engine
without a properly working thermostat and radiator cap.
To improve cold weather starting:
Use Preheat switch (see Section 6-1).
Keep battery in good condition. Store
battery in warm area.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel information.
Use correct grade oil for cold weather
(see Section 8-3).
5-7. Connecting To Weld Output Terminals
Stop engine.
1
Work (−) Weld Output Terminal
2
CV (Wire) Weld Output Terminal
3
CC (Stick/TIG) Weld Output Terminal
Stick and TIG Welding
For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect electrode
holder cable to CC (Stick/TIG) terminal on
right and work cable to Negative (−) terminal
on left.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
Use Process/Contactor switch to select type
of weld output (see Section 6-3).
MIG and FCAW Welding
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP, connect wire feeder cable to CV (Wire) terminal on right and
work cable to Work/Negative (−) terminal on
left. Use Process/Contactor switch to select
type of weld output (see Section 6-3).
2
3
1
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
Tools Needed:
1
2
3
3/4 in
803 562 / 214 778-B
5-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Stop engine before
connecting to weld output terminals.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
Do not use worn, damaged, undersized, or
poorly spliced cables.
* This
10 − 100% Duty Cycle
chart is a general guideline and may not suit all applications. If cables 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.
Return To Table Of Contents
OM-4422 Page 25
5-9. Connecting To Remote 14 Receptacle RC14
Socket*
Socket Information
A
24 volts ac. Protected by circuit
breaker CB8.
B
Contact closure to A completes
24 volt ac contactor control
circuit.
C
Output to remote control:+10
volts dc in MIG mode; 0 to +10
volts dc in Stick or TIG mode.
D
Remote control circuit common.
E
DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
24 VOLTS AC
REMOTE
OUTPUT
CONTROL
LDR-14 long
distance remote
(includes 120 V
receptacle)
I
115 volts, 10 amperes, 60 Hz
ac. Protected by circuit breaker
CB7.
J
Contact closure to I completes
115 volt ac contactor control
circuit.
F
Current feedback: 1 volt per
100 amperes.
115 VOLTS AC
OR
H
Voltage feedback: 1 volt per 10
arc volts.
GND
K
Chassis common.
NEUTRAL
G
Circuit common for 24 and 115
volt ac circuit.
803 562
*The remaining sockets are not used.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4422 Page 26
Return To Table Of Contents
Notes
Start Your Professional
Welding Career Now!
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
Return To Table Of Contents
Over 80,000 trained
since 1930!
OM-4422 Page 27
SECTION 6 − OPERATING WELDING GENERATOR
6-1. Front Panel Controls (See Section 6-2)
6
7
8
9
10
1
2
4
5
3
214 778-B / 803 563
OM-4422 Page 28
Return To Table Of Contents
6-2. Description Of Front Panel Controls (See Section 6-1)
Engine Starting Controls
Engine Gauges, Meters, And Lights
7
1
4
See Section 6-3 for Process/Contactor
switch information.
Preheat Switch
Use switch to energize starting aid for cold
weather starting (see starting instructions following).
2
Engine Control Switch
Use switch to start engine, select engine
speed (if unit has auto idle option), and stop
engine.
In Run position, engine runs at weld/power
speed. In Auto position (optional), engine
runs at idle speed at no load and weld speed
with load applied.
3
Engine Stop Lever
Use lever to stop engine if Engine Control
switch does not work.
The Engine Stop lever shuts off the fuel
supply. However, the Engine Stop lever
will not stop the engine if the engine can
draw fuel-rich air from the surrounding
atmosphere (oil refineries).
To Start:
Do not use ether.
If engine does not start, let engine come
to a complete stop before attempting restart.
Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
Below 325 F (05 C): turn engine control switch
to Auto position. Push Preheat switch up for
60 seconds. Turn Engine Control switch to
Start. Release Engine Control switch and
Preheat switch when engine starts.
To Stop: turn Engine Control switch to Off
position.
Fuel Gauge/Hourmeter
Use gauge to check fuel level or total engine
operating hours.
To check fuel level or engine hours when engine is not running, turn Engine Control switch
to Run or Auto (optional) position.
5
Engine Indicator Light
Light goes on and engine stops if engine temperature exceeds 230° F (110° C) or engine
oil pressure is below 10 psi (69 kPa).
Normal engine temperature is 180 - 203
F (82 - 95 C). Normal oil pressure is 30
- 60 psi (207 - 414 kPa).
Do not run engine until trouble is
fixed.
8
Process/Contactor Switch
Voltage/Amperage Control
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage.
With Process/Contactor switch in any Wire
(MIG) position, use control to adjust voltage.
With Voltage/Amperage Adjust Switch in Remote position, control limits the remote amperage in Stick or TIG mode, but has no effect
in Wire (MIG) modes.
Weld Meters
Weld meters also work in combination to
display troubleshooting help codes (see
Section 8-11).
Weld Controls
9
6
Voltmeter displays preset voltage (MIG welding) with contactor off, and actual output voltage with the contactor on. Voltmeter displays
voltage at the weld output terminals, but not
necessarily the welding arc due to resistance
of cable and connections.
Remote Control Receptacle
Use receptacle to connect remote controls,
wire feeders, and tools.
When a remote control is connected to the
Remote receptacle, the Auto Sense Remote
feature automatically switches voltage/amperage control to the remote control (see Section 5-9).
With remote control connected, weld output is
determined by a combination of front panel
and remote control voltage/amperage settings.
If no remote control is connected to the Remote receptacle, the front panel Voltage/Amperage control adjusts voltage and amperage.
If a remote device connected to Remote
Receptacle RC14 is faulty or is disconnected, the meters display Help 25 (see
Section 8-11). Clear fault by stopping and
restarting the unit or by turning Process/
Contactor switch to another position.
Return To Table Of Contents
DC Voltmeter
To set voltage, turn contactor off and turn Process/Contactor switch to Wire position. Turn
V/A control until desired voltage is displayed
on Voltmeter. When welding is finished, voltmeter displays weld voltage and then defaults
to preset voltage.
10 DC Ammeter
Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
output amperage when welding.
To set amperage, turn Process/Contactor
switch to Stick or TIG position. Turn V/A control until desired amperage is displayed on
Ammeter. When welding is finished, ammeter
displays weld amperage and then defaults to
preset amperage.
OM-4422 Page 29
6-3. Process/Contactor Switch On CC/CV Models
1
1
Process/Contactor Switch
Weld output terminals are energized when Process/Contactor
switch is in a Weld Terminals Always On position and the engine
is running.
Use switch to select weld process and
weld output on/off control (see table below).
Place switch in Remote On/Off Switch
Required positions to turn weld output on
and off with a device connected to the
Remote 14 receptacle.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use Stick mode for air carbon arc
(CAC-A) cutting and gouging.
When switch is in Stick mode, select one
of four arc drive (dig) settings to provide
additional amperage during low voltage
(short arc length) conditions and prevent
“sticking” electrodes. Turn control from A
to D to increase arc drive (dig) from min
to max.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 6-4).
803 562 / 214 778
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Engine Auto Idle (Optional)
Remote On/Off Switch Required −TIG HF Required Or
Scratch Start
GTAW With HF Unit, Pulsing
Device, Or Remote Control
At Remote 14 Receptacle
Active
Remote On/Off Switch
Required − Stick
Stick (SMAW) With Remote On/Off
At Remote 14 Receptacle
Active
Remote On/Off Switch
Required − CV Feeder
Using Remote
MIG (GMAW)
w/Constant Speed Feeder
At Remote 14 Receptacle
Active
Weld Terminals Always On −
Wire
MIG (GMAW)
w/Voltage Sensing Feeder
Electrode Hot
Active
Weld Terminals Always On −
Stick
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting
And Gouging
Electrode Hot
Active
Weld Terminals Always On −
TIG Lift-Arc
TIG Lift-Arc (GTAW)
Electrode Hot
Active
OM-4422 Page 30
Return To Table Of Contents
6-4. Lift-Arc Start Procedure
Lift-Arc TIG
With Lift-Arc TIG selected, start
arc as follows:
Lift-Arc Start Method
1
“Touch”
2
1−2
Seconds
1
TIG Electrode
2
Workpiece
Turn gas on. Touch tungsten
electrode to workpiece at weld start
point.
Hold
electrode
to
workpiece for 1-2 seconds, and
slowly lift electrode. Arc is formed
when electrode is lifted.
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 being contaminated.
Application:
Do NOT Strike Like A Match!
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to
replace the scratch method.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Return To Table Of Contents
OM-4422 Page 31
6-5. Remote Voltage/Amperage Control
1
Remote 14 Receptacle RC14
Connect optional remote control to RC14 (see
Section 5-9).
When a remote control is connected to the
1
Remote receptacle, the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control. When a device is connected to the Remote receptacle, remote voltage/amperage control is always available regardless
of the position of the Process/Contactor
switch.
In Example:
Process = Remote Stick
Min = 20 A DC
Max = 205 A DC
Example: Combination Remote Amperage Control (Stick)
Max (205 A DC)
Min (20 A DC)
Connect Remote
Control To Remote
Receptacle RC14
Set Remote Process
(Only If Remote On/Off
Control Is Desired)
Set V/A Control
Mid-Range: About 205A
Adjust Optional Remote Control
In Example:
Process =Remote TIG
Min = 20 A DC
Max = About 205 A DC
Example: Combination Remote Amperage Control (TIG)
Max (205 A DC)
Min (20 A DC)
Connect Remote
Control To Remote
Receptacle RC14
Set Remote Process
(Only If Remote On/Off
Control Is Desired)
Set V/A Control
Mid-Range: About 205 A
Adjust Optional Remote Control
0774 / Ref. 214 778-B / 803 562
OM-4422 Page 32
Return To Table Of Contents
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. 120 Volt And 240 Volt Receptacles
1
3
2
4
5
6
214 778-B
1
120 V 20 A AC GFCI
Receptacle GFCI1
2
120 V 20 A AC GFCI
Receptacle GFCI2
3
240 V 50 A AC
Receptacle RC3
GFCI1 and GFCI2 supply 60 Hz singlephase power at weld/power speed.
Maximum output from GFCI1 or GFCI2 is
2.4 kVA/kW.
If a ground fault is detected, GFCI Reset
button pops out and receptacle does not
work. Check for faulty equipment plugged
in receptacle. Press button to reset GFCI
receptacle.
At least once a month, run engine at
weld/power speed and press test button to verify GFCI is working properly.
RC3 supplies 60 Hz single-phase power at
weld/power speed. Maximum output from
RC3 is 10 kVA/kW.
4
Circuit Breaker CB4
5
Circuit Breaker CB6
6
Circuit Breaker CB5
CB4 protects GFCI2 and CB6 protects
GFCI1 from overload. If a circuit breaker
opens, the receptacle does not work. Press
button to reset breaker.
Circuit breaker CB5 protects receptacles
GFCI, GFCI2, RC3 and the generator windReturn To Table Of Contents
ing from overload. If CB5 opens, the receptacles do not work. Place CB5 switch in On
position to reset circuit breaker.
If a circuit breaker continues to open,
contact Factory Authorized Service
Agent.
Generator power decreases as weld
output increases.
Combined output of all receptacles is limited to the 10 kVA/kw rating of the generator.
EXAMPLE: If 15 A is drawn from each 120
V receptacle , only 26 A is available at the
240 V receptacle:
2 x (120 V x 15 A) + (240 V x 26 A) =
10.0 kVA/kW
OM-4422 Page 33
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. 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
Engine Manual and Maintenance
Label for important start-up, service,
and storage information. Service unit
more often if used in severe conditions.
*
To be done by Factory Authorized
Service Agent.
Every 8 h
Coolant
Full
Wipe
Up
Spills.
Check Fluid
Levels. See
Section 5-6.
OIL
Full
Every 50 h
Clean And
Tighten
Weld
Terminals.
Clean Air Filter.
See Section 8-4.
Every 100 h
Clean And
Tighten
Battery
Connections.
Check air cleaner
hoses for cracks
and loose clamps.
Every 250 h
Replace
Unreadable
Labels.
Change Oil. See
Section 8-9.
OM-4422 Page 34
1/2 in.
(13 mm)
Change Oil Filter.
See Section 8-9.
Return To Table Of Contents
Check Belt
Tension.
Check And
Clean Spark
Arrestor. See
Section 8-5.
Every 500 h
Change Secondary
(Canister) Fuel Filter.
See Section 8-9.
Replace primary (in-line)
fuel filter. See Section
8-9.
Repair Or
Replace
Damaged
Cables.
Every 1000 h
Check Radiator
Fluid Level. See
Section 5-6.
OR
Drain Sludge
From Fuel
Tank. See
Section 8-9.
FUEL
SLUDGE
Blow Out Or
Vacuum Inside.
During Heavy
Service,
Clean Monthly.
Service Welding
Generator Brushes And
Slip Rings. Service More
Often In Dirty Conditions.*
Check
Valve
Clearance.*
Every 2000 h
Clean/Set Injectors.*
8-2. Caterpillar Customer Assistance
Service
2
When a problem arises concerning the operation or service of the engine, the problem will normally be managed by the dealer
in your area.
If your problem cannot be resolved at
the dealer level without additional
assistance, call a Field Service
Coordinator at 1-800-447-4986.
Please follow the above steps in sequence
if a problem arises.
3
If your needs still have not been met,
submit the matter in writing to:
www.caterpillar.com
Your satisfaction is a primary concern to
Caterpillar and to Caterpillar dealers. If you
have a problem that has not been handled
to your complete satisfaction, follow these
steps:
1
Discuss your problem with a manager
from the dealership.
Caterpillar Inc.
Manager, Customer Service,
Engine Division
Mossville Bldg A
P.O. Box 600
Peoria, IL 61552-0600
Return To Table Of Contents
Website Address
Altitude
Contact the Caterpillar applications department for information on the effect of ambient
conditions on Caterpillar 3024 engines.
OM-4422 Page 35
8-3. Maintenance Label
OM-4422 Page 36
Return To Table Of Contents
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.
Optional
5
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
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
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.
Inspect
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 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 214 778-B
Return To Table Of Contents
OM-4422 Page 37
8-5. Inspecting And Cleaning Optional Spark Arrestor Muffler
Stop engine and let cool.
1
Spark Arrestor Muffler
2
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3
3
Exhaust Pipe
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
Stop engine and let cool.
1
Reinstall cleanout plug.
2
Tools Needed:
3/8 in
803 582 / Ref. 214 778-B
8-6. Servicing Engine Cooling System
Stop engine and let cool.
1
Radiator Draincock
2
Radiator Cap Cover
Change coolant according to engine
manual. Add coolant according to Section 5-6).
2
Run engine until engine reaches normal
operating temperature. Check coolant
level in recovery tank. Add coolant if necessary.
After engine cools, check coolant level
again and add coolant if necessary.
1
803 563
OM-4422 Page 38
Return To Table Of Contents
8-7. Adjusting Engine Speed On Standard Models
Stop engine and let cool.
Engine Speed
(No Load)
RPM (Hz)
Weld/Power
1850 (61.7)
Maximum
Engine speed is factory set and
should not require adjustment. After tuning engine, check engine
speed with tachometer or frequency meter. See table for proper no
load speed. If necessary, adjust
speed as follows:
Start engine and run until warm.
Turn Process/Contactor switch to
Weld Terminals Always On − Stick
position.
1 Lock Nut
2 Adjustment Screw
3
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
Do not set engine speed higher
than specified.
3
Engine Stop Lever
Stop engine.
Close door.
2
1
803 563
Return To Table Of Contents
OM-4422 Page 39
8-8. Adjusting Engine Speed On Models With Automatic Idle (Optional)
Engine Speed
(No Load)
1880 rpm max
(62.6 Hz)
1250 rpm
(41.6 Hz)
After tuning engine, check engine speed
with tachometer or frequency meter. See
table for proper no load speed. If necessary, adjust speed as follows:
Start engine and run until warm.
Turn Process/Contactor switch to Stick −
Weld Terminals Always On position.
Idle Speed Adjustment
1
Throttle Rod/Plunger
2
Locknut
Loosen locknut. Place Engine Control
switch in Auto position.
Turn throttle rod and plunger until engine
runs at idle speed. Tighten locknut.
Be sure solenoid plunger pulls all the
way in (“bottoms”) when energized.
If necessary, move linkage to other
hole in bracket or move cotter pin to
other hole in throttle arm to set idle
speed correctly.
Weld/Power Speed Adjustment
3
Engine Weld/Power Speed
Adjustment Screw
4
Locknut
Place Engine Control switch in Run position.
Loosen locknut. Turn screw until engine
runs at weld/power speed. Tighten locknut.
3
Do not set engine speed higher than
specified.
Stop engine.
4
If necessary, move
linkage to other hole in
bracket or move cotter
pin to other hole in
throttle arm to set idle
speed correctly.
2
1
803 563
OM-4422 Page 40
Return To Table Of Contents
8-9. Servicing Fuel And Lubrication Systems
Stop engine and let cool.
After servicing, start engine
and check for fuel leaks.
Stop engine, tighten connections as necessary, and wipe
up spilled fuel.
1
2
3
Oil Filter
Oil Drain Valve And Hose
Oil Fill Cap
4
Primary (Canister) Fuel Filter
5
Secondary (In-Line) Fuel
Filter
6
Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve
through hole in base. See engine
manual and engine maintenance
label for oil/filter change information.
To replace primary (canister) fuel
filter:
6
Turn filter counterclockwise. Remove filter.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new filter. Install new filter and turn clockwise.
Inspect fuel lines, and replace if
cracked or worn.
To drain water from fuel system:
See engine manual.
2
To replace secondary (in-line)
fuel filter:
Note direction of fuel flow as indicated by arrow on side of filter. Remove fuel line clamps and disconnect fuel lines from fuel filter. Replace filter, reconnect fuel lines, and
reinstall clamps.
4
To drain sludge from fuel tank:
Beware of fire. Do not smoke
and keep sparks and flames
away from drained fuel. Dispose of drained fuel in an environmentally-safe manner.
Do not leave unit unattended
while draining fuel tank.
Properly lift unit and secure
in a level position. Use adequate blocks or stands to
support unit while draining
fuel tank.
5
Attach 1/2 ID hose to drain valve.
Put metal container under drain,
and use screwdriver to open
sludge drain valve. Close valve
when sludge has drained. Remove
hose.
Close door.
Tools Needed:
3
1
802 490 / Ref. 801 434
Return To Table Of Contents
OM-4422 Page 41
8-10. Overload Protection
Stop engine.
When a circuit breaker or fuse
opens, it usually indicates a
more serious problem exists.
Contact Factory Authorized
Service Agent.
1
Fuse F1
F1 protects the stator exciter winding from overload. If F1 opens, weld
and generator power is low or stops
entirely.
2
3
Circuit Breaker CB1 (Not
Shown)
Circuit Breaker CB2
4
Circuit Breaker CB3
5
Circuit Breaker CB7
6
Circuit Breaker CB8
CB1 protects the engine battery circuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
when the fault is corrected.
CB2 protects the engine wiring harness. If CB2 opens, the engine will
not crank.
1
3
CB3 protects part of the weld control
wiring harness. If CB3 opens, weld
and generator power output stops.
CB7 protects the 115 volt ac output
to remote receptacle RC14. If CB7
opens, 115 volt output to RC14
stops.
CB8 protects the 24 volt ac output to
remote receptacle RC14. If CB8
opens, 24 volt output to RC14 stops.
Press button to reset breaker.
4
5
6
803 562 / 803 566
OM-4422 Page 42
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8-11. Voltmeter/Ammeter Help Displays
Use the Voltmeter/Ammeter help
displays to diagnose and correct
fault conditions.
1
When a help code is displayed
HL.P
normally weld output has
stopped but generator power
output may be okay.
20
To
2
HL.P
21
3
HL.P
22
4
reset help displays, stop
unit and then restart. See item
6 below to reset Help 25 display.
1
2
HL.P
23
5
24
HL.P
25
6
Help 21 Display
Indicates thermistor TH1 on the
main rectifier heat sink has failed.
If this display is shown, have Factory Authorized Service Agent check
TH1., and the wiring between TH1
and PC1.
3
HL.P
Help 20 Display
Indicates a failure of meter display
module PC2, or the wiring between
PC2 and main control module PC1.
If this display is shown, have Factory Authorized Service Agent check
PC1, PC2, and the wiring between
PC1 and PC2.
Help 22 Display
Indicates the rectifier heat sink has
overheated. If this display is shown,
check generator cooling system
and/or reduce duty cycle. Keep engine access door closed when running to maintain proper cooling air
flow past rectifier. Allow unit to cool
before restarting. If problem continues, have Factory Authorized Service Agent check unit.
4
Help 23 Display
Indicates one of the rectifier output
SCR’s has failed. If this display is
shown, have Factory Authorized
Service Agent check the rectifier
SCR’s.
5
Help 24 Display
Indicates weld open circuit voltage
(OCV) is too high (above 41 volts
dc). If this display is shown, have
Factory Authorized Service Agent
check main control module PC1.
6
Help 25 Display
Indicates a remote device connected to Remote Receptacle
RC14 may be faulty. Help 25 is also
displayed whenever a remote device has been connected to RC14
and then disconnected. Clear fault
by stopping and restarting the unit
or by turning Process/Contactor
switch to another position. If problem continues, have Factory Authorized Service Agent check the remote device, filter board PC6, and
main control module PC1.
803 562 / 214 778-B
Return To Table Of Contents
OM-4422 Page 43
8-12. Troubleshooting
Note
Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see
Section 8-11).
A. Welding
Trouble
Remedy
No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at ac receptacles.
On/Off Switch Required position and turn remote contactor on (see Section 5-9).
Reset circuit breaker CB7 or CB8 (see Section 8-10). Check for faulty remote device connected to RC14.
Check and secure connections to Remote Control receptacle RC14 (see Section 5-9).
Check Voltmeter/Ammeter help displays (see Section 8-11).
No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Reset circuit breaker CB3. (see Section 8-10).
Check fuse F1, and replace if open (see Section 8-10). If F1 is open, have Factory Authorized Service
Agent check the voltage regulator module PC3.
Check Voltmeter/Ammeter help displays (see Section 8-11).
Have Factory Authorized Service Agent check brushes and slip rings, voltage regulator module PC3, and
field excitation circuit.
Erratic weld output.
Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Have Factory Authorized Service Agent check brushes and slip rings.
High weld output.
Have Factory Authorized Service Agent check main control module PC1 and hall device HD1.
Low weld output.
Check engine speed, and adjust if necessary.
Check fuse F1, and replace if open (see Section 8-10). If F1 is open, have Factory Authorized Service
Agent check the rotor.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent check main control module PC1, voltage regulator module PC3,
and main rectifier.
No remote fine amperage control.
Repair or replace remote control device.
Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 5-9).
No 24 volt or 115 volt ac output at Re- Reset circuit breaker CB7 (24 volt) or CB8 (115 volt) (see Section 8-10).
mote receptacle RC14.
B. Standard Generator Power
Trouble
Remedy
No generator power output at ac recep- Reset receptacle circuit breakers (see Section 7-1).
tacles; weld output okay.
OM-4422 Page 44
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Trouble
No generator power or weld output.
Remedy
Disconnect equipment from generator power receptacles during start-up.
Check fuse F1, and replace if open (see Section 8-10). Have Factory Authorized Service Agent check
voltage regulator module PC3.
Reset circuit breaker CB3 (see Section 8-10).
Check Voltmeter/Ammeter help displays (see Section 8-11).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power ac re- Have Factory Authorized Service Agent check voltage regulator module PC3.
ceptacles.
Low output at generator power ac recep- Check engine speed, and adjust if necessary.
tacles.
Check fuse F1, and replace if open (see Section 8-10). If F1 is open, have Factory Authorized Service
Agent check the rotor.
C. Engine
Trouble
Engine will not crank.
Remedy
Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-10).
Have Factory Authorized Service Agent check engine wiring harness and components.
Reset circuit breaker CB2 (see Section 8-10).
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check Engine Control switch S1, and control relay CR2.
Engine cranks but does not start.
Check fuel level.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check control relay CR1, fuel solenoid FS1, and the fuel
pump.
Air in fuel system. See engine manual.
Engine hard to start in cold weather.
Use Preheat switch (see Section 6-1).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 8-3).
Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow
plug.
Engine suddenly stops.
Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 5-6 ).
Reset circuit breaker CB1 and/or CB2 (see Section 8-10). Have Factory Authorized Service Agent
check engine alternator, engine harness, throttle solenoid TS1, fuel solenoid FS1, and the fuel pump.
Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, integrated rectifier SR2, fuel solenoid FS1, and the fuel pump.
See engine manual.
Engine slowly stopped and cannot be
restarted.
Check fuel level.
Check engine air and fuel filters (see Sections 8-4 and 8-9).
See engine manual.
Return To Table Of Contents
OM-4422 Page 45
Trouble
Battery discharges between uses.
Remedy
Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine idles, but does not come up to
weld speed (units with idle option only).
Have Factory Authorized Service Agent check idle module PC5 and current transformer CT1.
Check for obstructed throttle solenoid.
Engine does not run at idle speed
(units with idle option only).
Check for obstructed throttle solenoid.
Have Factory Authorized Service Agent check idle module PC5, and control relay CR4.
Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 10).
wetstacking occurs.
OM-4422 Page 46
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Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Return To Table Of Contents
OM-4422 Page 47
SECTION 9 − ELECTRICAL DIAGRAMS
Figure 9-1. Circuit Diagram For Welding Generator
OM-4422 Page 48
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219 228-A
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OM-4422 Page 49
SECTION 10 − RUN-IN PROCEDURE
run_in1 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.
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.
2
1
2
Do not idle engine longer than
necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generator is kept loaded during
run-in.
Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional engine run-in information.
OM-4422 Page 50
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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.
4
2
1
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or generator auxiliary power receptacle.
2 Welding Generator
Place V/A control in minimum position, and Output Selector switch (if
present) in either DC position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe
correct
polarity.
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator A/V control so load
equals rated voltage and current of
generator (see nameplate, rating
label, or the specifications section
in this manual).
3
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
Check oil level frequently during run-in; add oil if needed.
After one hour (minimum) place A/V
control in minimum position, then
turn off load bank to remove load.
Run engine several minutes at no
load.
Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0683
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OM-4422 Page 51
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 Resistance Grid
Use grid sized for generator rated
output.
1
Turn Off grid.
2 Welding Generator
Place V/A control in minimum position, and Output Selector switch (if
present) in either DC position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connectors (polarity is not important).
4
Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
3
5
4
Start engine and run for several
minutes.
Set grid switches and then adjust
generator A/V control so load
equals rated voltage and current of
the generator (see nameplate, rating label, or the specifications section in this manual).
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
Check oil level frequently dur-
+
ing run-in; add oil if needed.
After one hour (minimum), place
A/V control in minimum position,
then shut down grid to remove load.
Run engine several minutes at no
load.
Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
OM-4422 Page 52
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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.
Return To Table Of Contents
S-0854
OM-4422 Page 53
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.
Use ground device as stated
in electrical codes.
2
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-4422 Page 54
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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
Return To Table Of Contents
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-4422 Page 55
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-4422 Page 56
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
Return To Table Of Contents
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
Return To Table Of Contents
OM-4422 Page 57
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-4422 Page 58
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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
Return To Table Of Contents
OM-4422 Page 59
SECTION 12 − PARTS LIST
Hardware is common and not
available unless listed.
Wirng harnesses are listed at
the end of parts section.
8
9
10
11
13
12
6
7
4
14
15
5
23
16
105
22
17
104
20
19
21
3−Fig.12-5
2
95
18
96
103
93
94
89
90
1−Fig.12-3
101
86
102
84
100−Fig.12-2
87
83
88
92
82
91
81
97
98
99
Figure 12-1. Main Assembly
OM-4422 Page 60
Return To Table Of Contents
29
28
26
25
30
27
39
38
33
24
37
32
31
36
30
35
71
72
70
34
69
68
67
62
79
73−Fig.12-4
80
66 64
63
61
60
58
65
40
41
46
42
48
47
42
44 45
43
49
59
78
57
77
50
56
54
55
74
55
76
75
53
51
52
803 683-A
Return To Table Of Contents
OM-4422 Page 61
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
. . . 1 . . . . . . . . . . Figure 12-3 . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . 217070 . . Bracket, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . Figure 12-5 . . Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . 214742 . . Capacitor Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 213489 . . . . Bus Bar, Capacitor Bank Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 213490 . . . . Bus Bar, Capacitor Bank Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . C10 . . . . 163535 . . . . Capacitor, Elctlt 16000 Uf 60 Vdc Can 1.75 Dia . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 181853 . . Insulator, Screw (For Rectifier Mtg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . Z1 . . . . . 213929 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 192303 . . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . . 215522 . . Bracket, Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . +213488 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . PC1 . . . . 214769 . . Module, Main Control/Scr Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . PC3 . . . . 214770 . . Module, Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . . 213493 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . 213501 . . Bracket, Fuel Pump/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Fuel Filter Mtg. (Order Thru Engine Manufacturer) . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . 217687 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . 207721 . . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . *213858 . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . 214753 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . 213602 . . Gasket, Exhaust Outlet Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . 212621 . . Pipe, Exhaust Flexible Inlet Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . 183314 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . 212604 . . Baffle, Air Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . 201528 . . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . 212605 . . Pipe, Exhaust Blue Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . +213470 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . 176104 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . 201851 . . Cover, Radiator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . 214604 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . 176230 . . Label, Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . 176103 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . 213472 . . Keeper, Latch Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . 213471 . . Bracket, Cover Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . 217387 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . 213503 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . +212607 . . Shroud, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . 212606 . . Radiator, W/14# Cap 3 Row Core 1.25 In Inlet/Outlet (Includes) . . . . . . .
. . . 38 . . . . . . . . . . . . . . 212603 . . Baffle, Air Upper Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . . . +213469 . . Upright, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . . . 190190 . . Tank, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . . . 213502 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . . . . . . . . . 176106 . . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . . . . 217698 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 44 . . . . . . . . . . . . . . 176108 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . .
. . . 45 . . . . . . . . . . . . . . 176109 . . Label, Caution Using Ether To Aid Engine Etc . . . . . . . . . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . . . . . 215268 . . Label, Diesel Engine Maintenance Cat 3013c . . . . . . . . . . . . . . . . . . . . . . .
. . . 47 . . . . . . . . . . . . . . 199592 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 48 . . . . . . . . . . . . . +213487 . . Door, Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 49 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . . . 087341 . . Bumper, Door 1.000 Od X .750 High Rbr 50 Duro W/O . . . . . . . . . . . . . .
OM-4422 Page 62
Return To Table Of Contents
1
1
1
1
1
1
6
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
15
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
2
2
2
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . . 51 . . . . . . . . . . . . . . 213486 . . Panel, Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦214887 . . Idle, Solenoid Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . ♦213505 . . . . Bracket, Mtg Solenoid Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . TS1 . . ♦080517 . . . . Solenoid,12vdc Pull Type Tubular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . ♦049839 . . . . Bracket, Adjustment Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦605277 . . . . Pin,Cotter .093 X .750 Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦198370 . . . . Rod,Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦206209 . . . . Ball Joint,.250−28 Thd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦198609 . . . . Arm,Throttle 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦085963 . . Spring, Ext .375 Od X .041 Wire X 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . 213266 . . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 56 . . . . . . . . . . . . . . 197506 . . Screw, M14−1.5x 30 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 57 . . . . . . . . . . . . . . 213480 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 58 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 59 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 2
. . . 60 . . . . . . . . . . . . . . . . . . . . . . . . Washer, Oil Drain (Order Thru Engine Manufacturer) . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 212612 . . Ftg, Adapter Oil Drain Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 197448 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Ft.
. . . 64 . . . . . . . . . . . . . . 176529 . . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 212614 . . Hose, Radiator Lower Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 217686 . . Belt, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 210792 . . Engine, Cat Dsl Elec 3013c (1800) Series (Includes) . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 212600 . . . . Flywheel, Cat 3013c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *202166 . . Filter, Oil Cat−150−4140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 217695 . . Switch, Coolant Temp N.c. 110c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 217696 . . Switch, Lubricating Oil Pressure N.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . 212613 . . Hose, Radiator Upper Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 216811 . . Clip, Nut Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 71 . . . . . . . . . . . . . . 197613 . . Air Cleaner, Intake 5.250 In (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197675 . . . . Dust Ejector, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197677 . . . . Cover Assy, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197678 . . . . Body, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦*197679 . . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197829 . . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 212617 . . Hose, Air Intake Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . Figure 12-4 . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 213461 . . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 212623 . . Tank, Fuel (Includes Fuel Cap And Items Below) . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 181572 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 212611 . . . . Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 212610 . . . . Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . SENDER . . 213265 . . . . Sender, Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 172071 . . Clamp, Hose .520 − .605 Clp Dia Slfttng Black . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . 211961 . . Hose, Sae .312 Id X .560 Od X 16.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 213804 . . Hose, Sae .312 Id X .560 Od X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 191819 . . Hose, Sae .312 Id X .560 Od X 15.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 145054 . . Hose, Sae .187 Id X .410 Od X 26.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 81 . . . . . . . . . . . . . . 213465 . . Bolt, J Stl .312−18 X 7.250 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 82 . . . . . . . . . . . . . . 213466 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . BATT . . . . 146237 . . Battery, Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1
Return To Table Of Contents
OM-4422 Page 63
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . . 85 . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . . 213668 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 87 . . . . . . . . . . . . . . 200864 . . Label, Warning Do Not Weld On Base CE (Wordless) . . . . . . . . . . . . . . . . 2
. . . 88 . . . . . . . . . . . . . . 213458 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . . 213459 . . Crossmember, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . . 213460 . . Crossmember, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . . . 213462 . . Pad, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213670 . . Screw, 500−13x2.25 Hex Flange−hd Gr8 Pln Chem/Phys . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 92 . . . . . . . . . . . . . . 213463 . . Spacer/Snubber, Generator Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213600 . . Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 213464 . . Bracket, Battery Locator (In Base − Not Shown) . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . . 213485 . . Support, Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . . 213483 . . Support, Engine Rh Cat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . . . . . . . . . . 213504 . . Tray, Reactor&Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213491 . . Insulator, Capacitor Bank (Applies To Reactor /Redtifier Tray) . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213506 . . Bracket, Hold−Down Fuel Tank (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . . . . +213468 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . . . . . . . . . 200795 . . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 213477 . . Panel, Front Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . Figure 12-2 . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . ♦105370 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . . . 216347 . . Label, Rating Card Code 133 (Provide Serial No. When Ordering) . . . . . 1
. . 103 . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1
. . 104 . . . . R3 . . . . . 213027 . . Resistor, WW Tap 300 W 40 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . TE1 . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 215327 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 215 327.
* 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-4422 Page 64
Return To Table Of Contents
Hardware is common and not
available unless listed.
Wirng harnesses are listed at
the end of parts section.
11
10
12
8
9
13
7
14
15
6
16
5
4
1
25
17
3
2
24
23
18
19
37
36
26
27
22
20
35
21
28
29
30
31
34
32
33
803 684-A
Figure 12-2. Panel, Front w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 100)
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
. . . . . . . . . . . . . . 097926 . .
. . . . . . . . . . . . . . 072590 . .
. . . . . . . . . . . . . . 170391 . .
. . . . . . . . . . . . . . 190323 . .
. . . . . . . . . . . . . . 097922 . .
........................
. . . . PC6 . . . . 217008 . .
. . CB7, CB8 . . 083432 . .
. . . . . . . . . . . . . . 213655 . .
Knob, Pointer 2.375 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . .
Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . .
Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . .
Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . .
Nameplate, Control (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
Panel, Front Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return To Table Of Contents
1
1
1
2
1
1
1
2
1
OM-4422 Page 65
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-2. Panel, Front w/Components (Continued)
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10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
. . . . . . . . . . . . . . 214543 . .
. . . . . . . . . . . . . . 134201 . .
. . . . PC2 . . . . 214660 . .
. . . . . R1 . . . . . 214760 . .
. . . . . R2 . . . . . 193118 . .
. . . . . S4 . . . . . 021467 . .
. . . . . S1 . . . . . 212436 . .
. . . . . . . . . . . . . . 039047 . .
. . . . . . . . . . . . . . 010381 . .
. C13, 14, 15 . 128750 . .
. . . . . . . . . . . . . . 209056 . .
. . . . RC4 . . . . 182954 . .
........................
. . . . . . . . . . . . . . 213509 . .
. . GFCI1, 2 . . 151981 . .
. . C11, C12 . . 217054 . .
. . CB4, CB6 . . 093996 . .
. . . . CB5 . . . . 203026 . .
. . . . GRD . . . . 083030 . .
. . . . . . . . . . . . . . 010915 . .
. . . . . . . . . . . . . . 601836 . .
........................
. . . . . . . . . . . . . . 181169 . .
. . . . . . . . . . . . . . 186621 . .
. . . . . . . . . . . . . . 180735 . .
. . . . . . . . . . . . . . 039046 . .
. . FUEL/HM . . 214768 . .
. . . . . . . . . . . . . . 021385 . .
Enclosure, Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . .
Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . .
Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . .
Switch, Ignition 4 Position (Includes Knob) . . . . . . . . . . . . . . . . . . . . . . . .
Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . .
Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . . . .
Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . .
Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . .
Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 2p 50a 240vac Screw−90 . . . . . . . . . . . . . . . .
Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Weld Terminal (Order By Model & Serial No.) . . . . . . . . . . . . .
Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
4
1
1
1
1
1
2
3
3
4
1
1
1
2
2
2
1
1
4
3
1
3
3
3
1
1
1
♦Optional
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 215 327
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-4422 Page 66
Return To Table Of Contents
Hardware is common and not
5
available unless listed.
4
Wirng harnesses are listed at
the end of parts section.
3
2
6
7
8
1
9
10
11
12
13
803 689-A
14
Figure 12-3. Control Panel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-3. Control Panel (Figure 12-1 Item 1)
...
...
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...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
. . . . . . . . . . . . . . 214919
. . . . . . . . . . . . . . 129524
. . . . CR2 . . . . 214876
. . . . CB1 . . . . 190374
. . . . CR1 . . . . 199999
. . . . . . . . . . . . . . 046432
. . . . . F1 . . . . . 085874
. . . . . R4 . . . . . 214863
. . . . CR4 . . ♦090104
. . . . CR3 . . . . 197325
. . . . SR3 . . ♦035704
. . SR1, SR2 . . 035704
. . . . PC5 . . ♦214761
. . CB2, CB3 . . 083432
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . .
Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Dpst−no 30a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . .
Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . .
Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . .
Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Module, Pull To Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
1
1
1
1
1
2
1
2
♦Optional
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 215 327
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.
Return To Table Of Contents
OM-4422 Page 67
Hardware is common and not
5
available unless listed.
4
Wirng harnesses are listed at
the end of parts section.
6
7
3
1
2
8
9
10
11
12
13
14
20
19 18
17 16
803 686-A
15
Figure 12-4. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-4. Generator (Figure 12-1 Item 73)
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...
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...
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...
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
. . . ROTOR . . .
..............
..............
..............
..............
..............
..............
..............
..............
..............
. . STATOR . .
..............
..............
..............
..............
..............
..............
..............
..............
..............
212474
053390
192600
159918
212126
602211
192686
602211
192686
212641
212470
160943
167788
218552
047879
161306
126984
005614
125548
158832
. . Rotor, Generator 4 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . .
. . . . Fan, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Adapter, Engine Machined Cat 3013c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . .
. . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . .
. . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . .
. . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . .
. . Stud, Stl .375−16 1.625x 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . .
. . Brush, Assembly 2 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bar, Retaining Brushholder 2 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cap, Brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Brush w/Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Holder, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Holder, Brush Elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 010−32x .50 Hex Hd−slt Stl Pld Sq Cone Sems . . . . . . . . . . . . . .
1
1
1
1
1
6
6
6
6
4
1
1
4
1
1
2
2
2
1
2
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 215 327.
*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-4422 Page 68
Return To Table Of Contents
Hardware is common and not
6
available unless listed.
1
Wirng harnesses are listed at
the end of parts section.
3
2
7
10
8
5
4
9
803 685-A
Figure 12-5. Rectifier Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-5. Rectifier Assembly (Figure 12-1 Item 3)
....................
... 1 ..............
. . . 2 . . MOD1,2,3 . .
. . . 3 . . MOD4,5,6 . .
... 4 ..............
... 5 ..............
... 6 ..............
. . . 7 . . . . TH1 . . . .
. . . 8 . . . . C1−6 . . . .
. . . 9 . . . C7,8,9 . . .
. . . 10 . . . . . . . . . . . . . .
....................
217081
211984
218296
218292
212602
212639
212601
213930
215611
048420
217085
181853
. . Rectifier, Assembly (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead . . . . . . . . . . . . . . . . .
. . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Screw (For Mounting Rectifier) . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
3
3
1
3
1
1
3
3
1
4
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.
Return To Table Of Contents
OM-4422 Page 69
Note
Item
No.
Some wiring harness components (switches, relays, circuit breakers) are also referenced
elsewhere in this parts list. Purchase components separately or as part of the associated
wiring harness.
Dia.
Mkgs.
Part
No.
Description
Quantity
Wiring Harnesses
....................
. . . . . . . . . . . S4 . . . . .
. . . . . . . . SR1, SR2 . .
. . . . . . . . . . CB1 . . . .
. . . . . . . . CB2, CB3 . .
. . . . . . . . . . CR3 . . . .
. . . . . . . . . . CR4 . . . .
. . . . . . . . . . . R4 . . . . .
....................
....................
....................
. . . . . . . . . . PLG1 . . . .
....................
....................
. . . . . . . . . For S1 . . .
. . . . . . . . . For S1 . . .
....................
219231
021467
035704
190374
083432
197325
214876
214863
148850
212116
212117
214932
214933
214934
211292
211293
129524
. . Harness, Engine Cat 3013c (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . .
. . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . .
. . . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . .
. . . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . .
. . . . Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . .
. . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Pack 4p 1row Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . .
. . . . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . .
1
1
2
1
2
1
1
1
1
3
3
1
7
1
1
1
2
....................
. . . . . . . . . . PLG2 . . . .
. . . . . . . . . . PLG9 . . . .
....................
....................
. . . . . . . . . . PLG8 . . . .
. . . . . . . . . . PLG6 . . . .
. . . . . . . . . . PLG7 . . . .
. . . . . . . . . . PLG9 . . . .
. . . . . . . . . PLG10 . . .
....................
....................
. . . . . . . . . . PLG5 . . . .
....................
....................
....................
217002
150316
214951
214933
214934
147992
193184
193183
215261
215262
215265
215343
113750
217000
215340
214933
. . Harness, Weld Control (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal . . . . . . . . . . . . . .
. . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Seal, Plug Deutsch 12−16 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S . . . . . . . . . . . . .
. . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
1
1
1
1
1
2
7
1
1
1
2
....................
. . . . . . . . . PLG11 . . .
....................
....................
214984
193183
207716
207718
. . Harness, Rectifier Cc/Cv (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Faston Mini Polarized 2 Skt G1k1 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Faston Mini Polarized 2 Skt G2k2 . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
6
3
. . . . . . . . . . . . . . . . . . . . 217010 . . Harness, Receptacle Auxiliary Power (Includes) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB4, CB6 . . 093996 . . . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . 2
OM-4422 Page 70
Return To Table Of Contents
Effective January 1, 2003
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
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.
Your distributor also gives
you ...
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.
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.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
*
*
*
*
*
*
*
Induction Heating Coils and Blankets
APT & SAF Model Plasma Cutting Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 8/03
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2004 Miller Electric Mfg. Co.
1/04
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