Miller | LC119875 | Owner Manual | Miller TRAILBLAZER 301 D User manual

Miller TRAILBLAZER 301 D User manual
OM-4410
206 933B
April 2002
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Plasma Cutting and Gouging
with Spectrum Unit
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
Trailblazer 301 D
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog orindividual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
WARNING
Battery posts, terminals
and related accessories
contain lead and lead
compounds, chemicals
known to the State of
California to cause
cancer and birth defects
or other reproductive
harm. Wash hands after
handling.
WARNING
The engine exhaust from
this product contains
chemicals known to the
State of California to
cause cancer, birth
defects, or other
reproductive harm.
The following terms are
used interchangeably
throughout this manual:
MIG = GMAW, Wire Welding
TIG = GTAW
Stick = SMAW
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
3
4
4
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
6
7
8
8
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Stick And MIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. TIG Mode Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Fuel Consumption While Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Fuel Consumption While Using Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
10
11
12
13
13
14
14
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Adding Coolant To Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Remote Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Adjusting Wire (MIG) Weld Puddle Consistency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
16
17
18
19
19
20
21
21
22
SECTION 5 – OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Description Of Front Panel Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Remote Amperage/Voltage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24
25
26
27
SECTION 6 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Auxiliary Power Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Optional GFCI Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Wiring Optional 240 Volt Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
28
29
29
(Continued)
TABLE OF CONTENTS
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Servicing Engine Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
30
32
33
34
35
36
39
SECTION 8 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Welding Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Auxiliary Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
40
41
41
SECTION 9 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
SECTION 10 – RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
46
47
48
SECTION 11 – AUXILIARY POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
SECTION 12 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
OPTIONS AND ACCESSORIES
WARRANTY
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
rom _nd_11/98
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters.
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
ARC RAYS can burn eyes and skin.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first – double-check connections.
Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes from arc rays and sparks when welding or
watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-4410 Page 1
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
HOT PARTS can cause severe burns.
Allow cooling period before maintaining.
Wear protective gloves and clothing when
working on a hot engine.
Do not touch hot engine parts or just-welded
parts bare-handed.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
CYLINDERS can explode if damaged.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Engine Hazards
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank – allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
OM-4410 Page 2
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before completely
removing cap.
MOVING PARTS can cause injury.
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
Stop engine before installing or connecting unit.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (–) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
BATTERY 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.
ENGINE EXHAUST GASES can kill.
Use equipment outside in open, well-ventilated
areas.
If used in a closed area, vent engine exhaust
outside and away from any building air intakes.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas – see applicable codes.
1-4. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, trailer, or any other
accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
FLYING SPARKS can cause injury.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or
stopping engine.
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
READ INSTRUCTIONS.
Use only genuine MILLER replacement parts.
Perform engine maintenance and service
according to this manual and the engine
manual.
OM-4410 Page 3
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-5. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
2. Arrange cables to one side and away from the operator.
OM-4410 Page 4
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT
UTILISATION
rom _nd_fre 11/98
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Identifie un message de sécurité particulier.
Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-5. Veuillez lire et respecter toutes
ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des composants.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès
que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact avec
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la
terre présentent un danger.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec
la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets et
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas
de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel
avec la pièce ou la terre.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation,
à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre
du sectionneur ou que la fiche du cordon est raccordée à une prise
correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de
mise à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct – ne pas utiliser le connecteur de pièce ou le câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
une électrode provenant d’une autre machine.
Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de
l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
Porter des vêtements de protection constitué dans une matière durable, résistant au feu (laine ou cuir) et une protection des pieds.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des
blessures ou des accidents mortels. S’assurer que l’air de respiration ne
présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et
tous les métaux renfermant ces éléments peuvent dégager des fumées
toxiques en cas de soudage.
OM-4410 Page 5
LE SOUDAGE peut provoquer un incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels que
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles peuvent être projetées de
l’arc de soudure. La projection d’étincelles, des pièces chaudes et des
équipements chauds peut provoquer des incendies et des brûlures. Le contact
accidentel de l’électrode avec des objets métalliques peut provoquer des
étincelles, une explosion, un surchauffement ou un incendie. Avant de
commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
Prévoir une période de refroidissement avant d’effectuer des travaux d’entretien.
Porter des gants et des vêtements de protection pour
travailler sur un moteur chaud.
Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
récemment soudées.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec
précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou
dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
substances inflammables.
Déplacer toutes les substances inflammables à une distance de 10,7 m de
l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec
des protections homologués.
Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des
ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés
correctement conformément à AWS F4.1 (voir les normes de sécurité).
Brancher le câble sur la pièce le plus près possible de la zone de soudage
pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et
d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porte-électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des gants
en cuir, une chemise en matériau lourd, des pantalons sans revers, des
chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches telles
qu’un allumeur au butane ou des allumettes.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Ne jamais souder une bouteille pressurisée – risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords convenables pour cette application spécifique; les maintenir ainsi
que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
les équipements associés et les publication P-1 CGA énumérées dans les
normes de sécurité.
1-3. Dangers existant en relation avec le moteur
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
OM-4410 Page 6
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Toujours vérifier le niveau de liquide de refroidissement dans le vase
d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme
suivant :
Mettre des lunettes de sécurité et des gants, placer un torchon sur le
bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
DES ORGANES MOBILES peuvent
provoquer des blessures.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas approcher les mains des ventilateurs, courroies et autres pièces en mouvement.
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
Arrêter le moteur avant d’installer ou brancher l’appareil.
Demander seulement à un personnel qualifié d’enlever les dispositifs de
sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux
d’entretien et de dépannage.
Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, débrancher le câble négatif (–) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles.
Remettre en place les panneaux ou les dipositifs de protection et fermer
les portes à la fin des travaux d’entretien et avant de faire démarrer le
moteur.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise
en route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention
sur le générateur.
L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.
Toujours porter une protection faciale, des gants en
caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher les câbles de
batterie.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide.
Observer la polarité correcte (+ et –) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier
lieu.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
LES GAZ D’ÈCHAPPEMENT DU
MOTEUR peuvent provoquer des
accidents mortels.
Utiliser l’équipement à l’extérieur dans des zones ouvertes et bien ventilées.
En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappement du moteur vers l’extérieur à distance des entrées d’air dans les bâtiments.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces inflammables.
Tenir à distance les produits inflammables de
l’échappement.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé –
voir codes en vigueur.
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
LA CHUTE DE L’APPAREIL peut
blesser.
Utiliser l’anneau de levage uniquement pour soulever
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.
Utiliser un équipement de levage de capacité suffisante pour lever l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
Porter un écran facial pour protéger le visage et les
yeux.
Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque
l’on porte l’équipement homologué de protection du visage, des mains et
du corps.
Les étincelles risquent de causer un incendie – éloigner toute substance
inflammable.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
LES
CHARGES
ÉLECTROSTATIQUES
peuvent
endommager les circuits imprimés.
Établir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
LE SURCHAUFFEMENT peut endommager le moteur électrique.
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
Utiliser les supports de la remorque ou des blocs
pour soutenir le poids.
Installer convenablement le poste sur la remorque
comme indiqué dans le manuel s’y rapportant.
Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur.
Ne pas laisser tourner le moteur trop lentement sous
risque d’endommager le moteur électrique à cause
d’une tension et d’une fréquence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a
lieu.
LIRE LES INSTRUCTIONS.
Utiliser seulement les pièces de rechange d’origine.
Effecteur la maintenance et la mise en service
d’après le manuel et celui du moteur.
OM-4410 Page 7
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements
de radio–navigation et de communication, les
services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées avec des
équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des sources
de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et et un blindage pour réduire les interférences
éventuelles.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible
électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que
le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
1-5. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
OM-4410 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
SECTION 2 – DEFINITIONS
2-1. Symbol Definitions
Stop Engine
Fast
(Run, Weld/Power)
Fast/Slow
(Run/Idle)
Slow (Idle)
Start Engine
Panel/Local
Temperature
Fuel
Engine Oil
Glow Plug
Check Valve
Clearance
Battery (Engine)
Engine
High Temperature
MIG (GMAW),
Wire
Stick (SMAW)
TIG (GTAW)
Circuit Breaker
Positive
Negative
Alternating Current
(AC)
Output
Time
Hours
Seconds
Protective Earth
(Ground)
h
A
s
Amperes
V
Volts
Do not switch while
welding
Remote
Receptacle
Work Connection
CC
Constant
Current
Wire Feed
Electrode
Positive
Electrode Negative
CV
Constant
Voltage
Read Operator’s
Manual
OM-4410 Page 9
SECTION 3 – SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
Welding
Process
Rated
Welding
Output
Maximum
Open-Circuit
Voltage
Amperage
Range In
CC Mode
Voltage
Range In
CV Mode
CC/AC
TIG
225 A, 25 V,
60% Duty Cycle
70
35 – 225 A
––
CC/DC
CV/DC
Stick/TIG
280 A, 25 V,
100% Duty
Cycle
80
MIG/FCAW
(Wire)
300 A, 25 V,
100% Duty
Cycle
50
20 – 300 A
––
Generator
Power Rating
––
Continuous: 9.5
kVA/kW, 80/40 A,
120/240 V AC, 60
Hz, Single-Phase,
10 – 33 V
Peak: 10 kVA/kW
(w/Weld Contactor
Off)
Fuel
Capacity
Engine
10 gal
(38 L)
Tank
Kubota D722
Water-Cooled,
Three-Cylinder,
Four-Cycle,
18.8 HP
Diesel Engine
3-2. Dimensions, Weights, and Operating Angles
Dimensions
Height
33 in (838 mm)
Width
18-3/4 in (476 mm)
Depth
45-1/2 in (1156 mm)
A
18 in (457 mm)
B
16-1/2 in (419 mm)
C
3/4 in (19 mm)
D
3-1/8 in (79 mm)
E
32-3/4 in (832 mm)
F
45-1/2 in (1156 mm)
G
13/32 in (10 mm) Dia.
Weight
690 lb (313 kg)
OM-4410 Page 10
A
B
C
Do not exceed tilt angles or engine could
be damaged or unit could tip.
D
G
4 Holes
Do not move or operate unit where it could
tip.
E
F
20°
20°
20°
20°
Engine End
800 426
803 111
3-3. Stick And MIG Mode Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
A. CC/DC Stick Mode
90
DC VOLTS
80
70
60
50
40
30
20
10
0
0
50
100
150
200
250
300
350
400
450
DC AMPERES
B. CV/DC MIG Mode
50
45
DC VOLTS
40
35
30
25
20
15
10
5
0
0
100
200
300
400
500
600
700
DC AMPERES
207 918 / 207 919
OM-4410 Page 11
3-4. TIG Mode Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
A. CC/AC TIG Mode
60
AC VOLTS
50
40
30
20
10
0
0
50
100
150
200
250
300
AC AMPERES
B. CC/DC TIG Mode
50
DC VOLTS
40
30
20
10
0
0
50
100
150
200
250
300
350
DC AMPERES
207 920 / 207 921
OM-4410 Page 12
US GAL/HR.
LITERS/HR.
3-5. Fuel Consumption While Welding
7.57 2.00
6.62 1.75
5.68 1.50
4.73 1.25
3.79 1.00
WELD – 3600 RPM
2.84 0.75
1.89 0.50
IDLE
0.95 0.25
0.00 0.00
0
50
100
150
200
250
300
DC WELD AMPERES AT 100% DUTY CYCLE
207 922
LITERS/HR.
US GAL/HR.
3-6. Fuel Consumption While Using Generator Power
4.54
1.20
3.79
1.00
3.02
0.80
2.27
0.60
1.51
0.40
0.76
0.20
0.00
0.00
IDLE
0
1
2
3
4
5
6
7
8
9
10
GENERATOR POWER KILOWATTS AT 100% DUTY CYCLE
207 923
OM-4410 Page 13
3-7. Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
100% Duty Cycle at 300 Amperes DC
Exceeding duty cycle can
damage unit and void
warranty.
Continuous Welding
325
DC/CV
300
275
DC/CC
WELD AMPERES
250
225
200
AC/CC
175
150
0
10
20
30
40
50
60
70
80
90
100
% DUTY CYCLE
207 925
3-8. Generator Power Curve
The ac generator power curve
shows the generator power available in amperes at the receptacles.
300
250
AC VOLTS
200
150
100
50
0
0
10
20
30
40
50
60
70
80
90
AC AMPERES
207 924
OM-4410 Page 14
SECTION 4 – INSTALLATION
4-1. Installing Welding Generator
Movement
Do not weld on base. Welding on base can cause fuel
tank fire or explosion. Bolt
unit down using holes provided in base.
Airflow Clearance
18 in
(460 mm)
Do not lift unit from end.
18 in
(460 mm)
18 in
(460 mm)
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
OR
18 in
(460 mm)
18 in
(460 mm)
Grounding
Location
Always securely fasten
welding generator onto
transport vehicle or trailer
and comply with all DOT and
other applicable codes.
1
2
3
4
3
1
GND/PE
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
4
If the unit does not have
GFCI receptacles, use GFCIprotected extension cord.
OR
OR
2
Electrically bond generator frame to vehicle frame
by metal-to-metal contact.
2
install1 10/00 – Ref. 800 652 / Ref. 800 477-A / 158 936-A / S-0854
Notes
OM-4410 Page 15
4-2. Engine Prestart Checks
Check all fluids daily. Engine must be cold
and on a level surface. Unit is shipped with
10W30 engine oil. Engine stops if oil pressure is low or engine temperature is high.
Check radiator coolant
level when fluid is low in
recovery tank.
Full
Full
Capacity: w/Overflow
Tank 6.9 qt (6.5 L)
Diesel
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.
Do not use ether to start engine.
Using ether voids warranty.
Add fresh diesel fuel before starting
engine the first time (see maintenance label for specifications). Leave filler neck
empty to allow room for expansion. Open
fuel shut-off valve.
Do not run out of fuel or air enters fuel system and causes starting problems. See
engine manual to bleed air from fuel
system.
Oil
After fueling, check oil with unit on level
surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).
Engine may use oil and wetstacking may occur during run-in. Check
oil several times daily during run-in
(first 100 hours).
Full
Open Valve
Coolant
Check coolant level in radiator before
starting unit the first time. Add coolant if below bottom of filler neck (see Section 4-3
for radiator filling instructions).
Check coolant level in recovery tank daily.
If coolant is below Cold Full level, add coolant until level in tank is between Cold Full
and Hot Full levels. If recovery tank coolant level was low, check coolant level in radiator (see Section 4-3).
Engine coolant is a mixture of water and
ethylene glycol base antifreeze. A solution
of 50% antifreeze and 50% water must be
used in this engine. Do not use 100% antifreeze or severe damage will occur.
Keep radiator and air intake clean.
Incorrect engine temperature can
damage engine. Do not run engine
without a properly working thermostat and radiator cap.
To improve cold weather starting:
Keep battery in good condition. Store
battery in warm area off concrete
surface.
Full
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel
information.
Coolant Recovery
Tank
Use correct grade oil for cold weather.
803 111 / 801 940 / 801 961
OM-4410 Page 16
4-3. Adding Coolant To Radiator
Stop engine and let cool.
Check coolant level according
to Section 4-2 before starting
this procedure.
If coolant level is below bottom of
radiator filler neck, add coolant as
follows:
Full
Capacity: w/Overflow
Tank 6.9 qt (6.5 L)
1 Thermostat Housing Plug
Remove thermostat housing plug.
Add coolant to radiator until coolant
is at bottom of filler neck and coolant trickles out of thermostat housing plug hole. This ensures all air is
purged from the system.
Reinstall plug and radiator cap.
Check coolant level in recovery
tank (see Section 4-2).
Engine coolant is a mixture of water
and ethylene glycol base antifreeze. A solution of 50% antifreeze
and 50% water must be used in this
engine. Do not use 100% antifreeze
or severe damage will occur.
1
Tools Needed:
8 mm
803 111 / 206 580
OM-4410 Page 17
4-4. 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
+
–
rubbergloves
30 A For 12 Minutes
glasses
drybatt1 1/98 – S-0886
OM-4410 Page 18
4-5. Connecting The Battery
Connect negative (–)
cable last.
+
–
Tools Needed:
3/8, 1/2 in
Ref. 801 939 / Ref. 206 580 / Ref. S-0756-D
4-6. Installing Exhaust Pipe
Stop engine and let cool.
Do not blow exhaust toward rear
of unit or air cleaner will require
frequent service. Point exhaust
pipe in desired direction but always away from front panel and
direction of travel.
Tools Needed:
1/2 in
801 681 / Ref 803 111 / Ref. 206 580
OM-4410 Page 19
4-7. Connecting To Weld Output Terminals
Stop engine.
Do not connect to CC and CV
terminals at the same time.
1
2
3
Work Weld Output Terminal
Stick/TIG (CC) Weld Output
Terminal
Wire /CV Weld Output Terminal
For MIG welding, connect work cable
to Work terminal and wire feeder
cable to Wire (CV) terminal.
For Stick/TIG welding, connect work
cable to Work terminal and electrode
holder cable to Stick/TIG (CC)
terminal.
1
2
3
803 112 / Ref. 206 580
OM-4410 Page 20
4-8. 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)
Do not use worn, damaged, undersized, or
poorly spliced cables.
10 – 100% Duty Cycle
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
4-9. Remote Receptacle Information
Socket*
A
B
K
J
I
H
C L N
D M
G
E F
Socket Information
A
24 volts ac.
B
Contact closure to A completes 24 volt ac contactor control circuit and keeps engine at Run speed
in all modes. Protected by circuit breaker CB5.
C
0 to +10 volts dc output to remote control in Stick
and TIG modes. +10 volts dc output to remote
control in Wire mode.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control with V/A control at max.
G
Circuit common for 24 volt ac circuits.
K
Chassis common.
24 VOLTS AC
V/A
VOLTAGE/
AMPERAGE
GND
*The remaining sockets are not used.
OM-4410 Page 21
4-10. Adjusting Wire (MIG) Weld Puddle Consistency
Stop engine and let cool.
Stabilizer DC-Z is factory connected to
suit most Wire (MIG) welding applications.
To change Wire (MIG) weld puddle consistency, proceed as follows:
Remove cover and right side panel.
1
Stabilizer DC-Z
2
Wire /CV Weld Output Terminal
3
Stabilizer Leads 29, 28, And 27
Lead 29 – provides stiffest weld
puddle
Lead 28 – provides wetter weld
puddle (for mild steel)
Lead 27 – provides wettest weld
puddle (for stainless steel)
Lead 29 is connected to the Wire/CV
weld output terminal at the factory.
Disconnect lead 29 from the Wire/CV
weld output terminal.
For wetter weld puddle (for mild
steel):
Remove insulated sleeving from lead
28. Connect lead 28 to Wire/CV weld
output terminal, reusing hardware. Insulate lead 29 with sleeving removed from
lead 28. Secure sleeving with cable ties.
For wettest weld puddle
(for stainless steel):
Remove insulated sleeving from lead
27. Connect lead 27 to Wire/CV weld
output terminal, reusing hardware. Insulate lead 29 with sleeving removed from
lead 27. Secure sleeving with cable ties.
Reinstall side panel.
1
2
3
Tools Needed:
3/8, 7/16 in
803 113
OM-4410 Page 22
Notes
OM-4410 Page 23
SECTION 5 – OPERATING WELDING GENERATOR
5-1. Front Panel Controls (See Section 5-2)
1
2
3
7
4
5
6
8
10
9
Ref. 206 580
OM-4410 Page 24
5-2. Description Of Front Panel Controls (See Section 5-1)
1 Process/Contactor Switch
See Section 5-3 for Process/Contactor
switch information.
2 Voltage/Amperage Adjust Switch And
Remote Receptacle
Use switch to select front panel or remote
voltage/amperage control. For remote control, place switch in Remote position and
connect remote control to Remote receptacle RC4 (see Sections 4-9 and 5-4).
3 V/A Control
Use control to select weld voltage or
amperage. Control may be adjusted while
welding.
With Process/Contactor switch in any Stick
or TIG setting, use control to adjust amperage. With Process/Contactor switch in either
Wire position, use control to adjust voltage.
With V/A Adjust Switch in Remote position,
control sets the maximum amperage in Stick
and TIG modes, but has no effect in MIG
modes.
4 Low Oil Pressure Light
Light goes on and engine stops if engine oil
pressure is too low.
Do not run engine until trouble is
fixed.
5 Engine Hour Meter
Use hour meter to help schedule maintenance (see Section 7-1).
6 High Engine Temperature Light
Light goes on and engine stops if engine
temperature is too high.
Do not run engine until trouble is
fixed.
7
Engine Control Switch
Use switch to start engine, select speed, and
stop engine. In Run/Idle position, engine
runs at idle speed at no load, and weld/power
speed under load. In Speed Lock position,
engine speed is determined by position of
Speed Lock switch (see item 8 and engine
speed table following).
9 Glow Plug Switch
If necessary, push switch down before startup to activate glow plug. See glow plug table
following for operating information.
Do not use glow plugs longer than 20
seconds.
Glow Plug Time
t
Place Engine Control switch in Speed
Lock position and Speed Lock switch in
Run position for TIG (GTAW) welding
using a high frequency device.
The unit
will not return to idle speed
when the remote contactor is on (closure between pins A and B on remote receptacle).
8
Speed Lock Switch
Use switch to lock engine in idle or weld/
power speed when Engine Control switch is
in the Speed Lock position. The idle lock
switch is not needed at start-up. The engine
always starts at idle speed.
With switch in the Idle position and Engine
Control switch in Speed Lock, the engine
runs at idle speed. With switch in Run position and Engine Control switch in Speed
Lock, engine runs at weld/power speed.
Speed Lock switch does not affect engine
speed when Engine Control switch is in Run/
Idle position. (Engine speed changes with
load.)
70°F (21°C)
32°F (0°C)
–4°F (–20°C)
0 seconds
10 seconds
20 seconds
To start:
Do not use ether to start engine.
Using ether voids warranty.
Use glow plug switch if necessary (see item
9 and glow plug table). Turn engine control
switch to Start. Release engine control
switch when engine starts.
If the engine does not start, let the en-
gine come to a complete stop before attempting restart.
To Stop: turn Engine Control switch to Off
position.
Close fuel valve to stop engine if Engine
Control switch does not work (see Section 4-2).
10 DC Polarity/AC Switch
Do not switch under load.
Use switch to select AC weld output or polarity of DC weld output.
Controlling Engine Speed
=
=
Any
position.
=
2450 rpm (Idle Speed)
Continuous
3750 rpm max (Weld/Power Speed)
Continuous.
Use in welding applications where high
speed is needed for better arc starting and
in TIG applications using a high frequency
arc starter.
No Load: 2450 rpm (Idle Speed)
Load: 3750 rpm max (weld/Power Speed)
OM-4410 Page 25
5-3. Process/Contactor Switch On CC/CV Models
1
1
Process/Contactor Switch
Weld output terminals are energized when Process/Contactor
switch is in an Electrode Hot position and the engine is running.
The unit will not return to idle speed
when the remote contactor is on
(closure between pins A and B on remote receptacle).
Use switch to select weld process and
weld output on/off control (see table below and Section 4-9).
Place switch in Remote positions to turn
weld output on and off with a device connected to the remote receptacle.
Place switch in Electrode Hot positions
for weld output to be on whenever the engine is running.
Use Stick positions for air carbon arc
(CAC-A) cutting and gouging.
When switch is in a Stick position, the dig
circuit provides additional amperage
during low voltage (short arc length conditions) to prevent “sticking” electrodes.
The dig circuit is disabled when switch is
in Wire or TIG positions.
803 112
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Remote – TIG
GTAW With HF Unit, Pulsing Device, Or
Remote Control
At Remote Receptacle
Remote – Stick
Stick (SMAW) With Remote On/Off
At Remote Receptacle
Remote – Wire
MIG (GMAW)/FCAW
At Remote Receptacle
Electrode Hot – Wire
MIG (GMAW)/FCAW
Electrode Hot
Electrode Hot – Stick
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting And Gouging
Electrode Hot
Electrode Hot – Scratch
Start TIG
Scratch Start TIG (GTAW)
Electrode Hot
OM-4410 Page 26
5-4. Remote Amperage/Voltage Control
1
Remote Receptacle RC4
Connect optional remote control to
RC4 (see Section 4-9).
2
3
Engine runs at weld/power speed
1
whenever a device connected to
the remote receptacle makes
closure between pins A and B
(example: trigger pull on MIG
gun).
Example: Combination Remote Amperage Control (Stick)
Set V/A Adjust
Switch
Remote Hand Control (Optional)
Remote Foot Control (Optional)
Example:
Process = Stick (Using Remote On/Off)
Min = 40 A CC/DC
Max = 180 A CC/DC
Set V/A
Control
Set Remote
Process
3
2
Max (180 A DC)
Min (40 A DC)
Select Polarity By
Using DC Polarity/AC
Switch Or By
Changing Cable
Connections
Adjust Remote Control
(Stick Welding Only)
802 850 / 206 580 / S-0769 / S-0774
OM-4410 Page 27
SECTION 6 – OPERATING AUXILIARY EQUIPMENT
6-1. Generator Power Receptacles And Circuit Breakers
If unit does not have GFCI receptacles,
use
GFCIprotected extension cord.
Generator power decreases as
5
6
weld current increases.
1
240 V 50 A AC Receptacle
RC1
RC1 supplies 60 Hz single-phase
power at weld/power speed. Maximum output is 9.5 kVA/kW.
1
2
120 V 20 A AC Duplex
Receptacle RC2
3
120 V 20 A AC Duplex
Receptacle RC3
RC2 and RC3 supply 60 Hz singlephase power at weld/power speed.
Maximum output from RC2 or RC3 is
2.4 kVA/kW.
4
Circuit Breaker CB1
CB1 protects receptacles RC1, RC2,
and RC3 from overload. If CB1
opens, the receptacles do not work.
Place switch in On position to reset
breaker.
4
2
3
5
Circuit Breaker CB3
6
Circuit Breaker CB4
CB3 protects RC2 and CB4 protects
RC3 from overload. If a circuit breaker opens, the receptacle does not
work. Press button to reset breaker.
If
circuit breaker continues to
open,
contact
Factory
Authorized Service Agent.
Combined output of all receptacles
limited to 9.5 kVA/kW rating of the
generator.
EXAMPLE: If 20 A is drawn from
each 120 V duplex receptacle, only
20 A is available at the 240 V
receptacle:
2 x (120 V x 20 A) + (240 V x 19 A) =
9.4 kVA/kW
Ref. 206 580
OM-4410 Page 28
6-2. Optional GFCI Receptacles
If unit does not have GFCI receptacles,
use
GFCIprotected extension cord.
1
Generator power decreases as
weld current increases.
Combined output of all receptacles
limited to 9.5 kVA/kW rating of the
generator.
GFCI Receptacle Option
1
120 V 20 A AC GFCI Receptacles GFCI-2 and GFCI-3
GFCI2 and GFCI3 supply 60 Hz
single-phase power at weld/power
speed. Maximum output from
GFCI-2 or GFCI-3 is 2.4 kVA/kW.
Circuit breaker protection is the
same as standard receptacles.
If a ground fault is detected, the
GFCI Reset button pops out and
the circuit opens to disconnect the
faulty equipment. Check for
damaged tools, cords, plugs, etc.
connected to the receptacle. Press
button to reset receptacle and
resume operation.
At
least once a month, run
engine at weld/power speed
and press Test button to verify
GFCI is working properly.
Ref. 206 580
6-3. Wiring Optional 240 Volt Plug
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
Current Available in Amperes
1
7
240 V
Each 120 V Duplex
Receptacle*
Receptacle
45
40
30
25
20
10
5
0
0
5
15
20
20
20
20
20
1
3
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
4
120V
120V
5
240V
6
2
3
V x A = Watts
Plug Wired for 120/240 V,
3-Wire Load
2
Plug Wired for 240 V, 2-Wire
Load
3
Neutral (Silver) Terminal
4
Load 1 (Brass)Terminal
5
Load 2 (Brass) Terminal
6
Ground (Green) Terminal
7
Amperes Available using
120/240 V Plug
4
*One 240 V load or two 120 V loads.
Tools Needed:
240V
6
5
120 813-D
OM-4410 Page 29
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING
7-1. Routine Maintenance
NOTE
Follow the storage procedure in the engine owner’s manual if the unit will not be
used for an extended period.
Recycle engine
fluids.
Stop engine before maintaining.
See also Engine Manual and
maintenance label. Service engine more
often if used in severe conditions.
* To be done by Factory Authorized
Service Agent.
8h
Check fluid levels.
See Section 4-2.
OIL
Full
Wipe up spills.
50 h
Clean and
tighten weld
terminals.
Check fuel lines
and connections.
75 h
Change oil. See Section 7-5
and maintenance label.
100 h
Service air filter
element (see
Section 7-3).
Check belt tension.
Clean and
tighten battery
connections.
Check air cleaner
hoses for cracks
and loose clamps.
Clean secondary
fuel filter.
5/16 in.
(8 mm)
150 h
Change oil filter.
Section
7-5
maintenance label.
OM-4410 Page 30
See
and
200 h
Replace primary
fuel filter. See
Section 7-5.
Check radiator
hoses
and
clamps.
Replace unreadable
labels.
400 h
Replace secondary fuel
filter (see Section 7-5).
500 h
Replace fan belt.
Flush radiator.
Repair or replace
cracked cables.
Service welding generator
brushes and slip rings. Service
more often in dirty conditions.*
800 h
Check valve
clearance.*
1000 h
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
OR
2000 h
Replace fuel
lines
and
clamps.
Replace radiator
coolant and hoses
(see Section 7-4).
OM-4410 Page 31
7-2. Maintenance Label
OM-4410 Page 32
7-3. 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
Inspect
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 2/01 – 153 929-B / 153 585 / Ref. S-0698-B
OM-4410 Page 33
7-4. Servicing Engine Cooling System
Stop engine and let cool.
1
Radiator Cap
2
Radiator Drain Cock
Drain engine coolant according to
procedure in engine manual.
Add engine coolant according to
procedure in Section 4-3.
1
2
801 939 / 802 727
OM-4410 Page 34
7-5. Servicing Engine Fuel And Lubrication Systems
Stop engine and let cool.
1
Oil Drain Valve
2
Oil Filter
Change engine oil and filter according to engine manual.
Close valve and valve cap
before adding oil and running engine.
Fill crankcase with new oil to full
mark on dipstick (see Section 7-2).
5
3
Fuel Lines
Replace fuel lines if cracked or
worn.
4
Primary Fuel Filter
Install new filter as shown.
5
Secondary Fuel Filter
Replace filter according to engine
manual.
Wipe up any spilled fuel.
Start engine, and check for fuel
leaks.
3
Stop engine, tighten connections as necessary, and wipe
up fuel.
4
3
2
1
Tools Needed:
Ref. 801 961 / 801 940 / Ref. 203 084 / S-0842
OM-4410 Page 35
7-6. Adjusting Engine Speed
NOTE
If the engine does not start and stop properly, verify the fuel solenoid is installed
properly before adjusting engine speed (see Section A following).
If the engine does not stay at idle speed, verify the throttle solenoid is installed and
adjusted properly before adjusting engine speed (see Section B following).
If the engine runs properly but the speeds are incorrect, do not adjust the
solenoids. Adjust the engine speed according to the instructions in Section C.
A. Checking Fuel Solenoid
Stop engine.
Tools Needed:
7/16 in
10, 14 mm
3
Verify mounting
bracket is recessed
from edge of engine.
If the engine does not start and stop when
using the Engine Control switch, check
the position of the fuel solenoid.
Adjusting Fuel Solenoid Position
1
2
3
Fuel Solenoid
Stop Screw
Fuel Solenoid Mounting Screws
Stop screw is factory-set and should
not be adjusted.
1
2
When properly adjusted, the solenoid
bracket is slightly recessed from the edge
of the engine block and the solenoid linkage easily travels between the stop screw
and the fuel solenoid internal stop.
Tighten mounting screws when
solenoid is in correct position.
If adjustment is necessary, loosen the solenoid mounting screws and push the solenoid bracket back toward engine as far
as possible.
Continue pushing on solenoid bracket in
a clockwise direction while tightening
mounting screws.
4
5
Shutdown Lever
Stop screw
6
Stop Screw Jam Nut
7
8
Fuel Solenoid Jam Nut
Plunger
Stop screw is factory-set and should
not be adjusted.
Hold throttle solenoid in idle (energized)
position. If shutdown lever is touching or
within 1/16 in of stop screw, fuel solenoid
is properly adjusted.
If lever is more than 1/16 in. from stop
screw, check for clearance between jam
nut and fuel solenoid. If there is clearance
between jam nut and solenoid, loosen nut
and turn plunger clockwise until lever
touches stop screw. Retighten nut.
8
6 5
7
If there is no clearance between jam nut
and solenoid, loosen the solenoid mounting screws and reposition the solenoid as
described at the beginning of this section.
4
Ref. 801 961 / 802 649
OM-4410 Page 36
B. Checking Throttle Solenoid
Stop engine.
If the engine does not stay at idle
speed, verify the the throttle solenoid and linkage is installed properly.
Adjusting Throttle Solenoid
1
2
3
1
2
3
4
5
6
7
5
Throttle Solenoid
Jam Nut
Solenoid Link
Shoulder Bolt
Throttle Lever
Solenoid Rod
Throttle Solenoid Mounting
Screw
Loosen jam nut, remove shoulder
bolt, and remove link from throttle
lever. Install link 5/8 in (16 mm) on
solenoid rod. Reconnect link to
shoulder bolt and throttle lever.
4
6
Push solenoid rod into idle (energized) position and check for nonbinding lateral movement of throttle
link at throttle lever. If link binds,
loosen solenoid mounting screws.
Move the solenoid slightly until the
link moves freely with solenoid in
relaxed and energized positions.
Tighten screws.
Tighten jam nut.
Go to Step C.
5/8 in
(16 mm)
Tools Needed:
3/8, 7/16 in
7
Check for non-binding
movement of link with solenoid in energized position.
5/32 in
Check for non-binding
movement of link with
solenoid in relaxed
position.
Ref. 801 961 / 802 649
OM-4410 Page 37
C. Making Engine Speed Adjustments
Before adjusting engine speed, verify
throttle solenoid is installed properly
(see Section B on previous page).
2450 ± 100 rpm
Idle
3750 Max
Weld/Power
Check engine speeds with a tachometer
(see table). If necessary, adjust speeds as
follows:
Start engine and run until warm. Turn V/A
control to max.
Adjusting Idle Speed
Turn Engine Control switch to Run/Idle
position.
1
2
3
4
5
Throttle Solenoid
Idle Speed Jam Nut
Plunger
Throttle Link
Throttle Lever
Loosen jam nut. While holding throttle link
with a 3/8 in wrench, turn plunger clockwise to increase idle speed or counterclockwise to decrease idle speed.
After adjusting idle speed, verify the
Be sure throttle link
is parallel with
throttle lever.
throttle link is parallel with the throttle
lever. If necessary, loosen the idle
speed jam nut and reposition the
throttle link.
Do not twist solenoid boot while adjusting engine speed.
Tighten jam nut.
6
7
Adjusting Weld/Power Speed
Start engine and run until warm. Turn V/A
control to max.
1
3
2
4
6
7
5
Do not twist
solenoid boot
while adjusting
engine speed.
Turn Engine Control switch to Run position. Loosen nut and turn screw counterclockwise to increase speed. Turn screw
clockwise to decrease speed. Tighten nut.
Tools Needed:
3/8, 7/16 in
10, 14 mm
OM-4410 Page 38
Weld Speed Jam Nut
Adjustment Screw
Ref. 801 961 / 801 963
7-7. Overload Protection
Stop engine.
Tools Needed:
When a circuit breaker or fuse
opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.
3/8 in
1 Circuit Breaker CB5
CB5 protects the 24 volt ac output
to Remote receptacle RC4. If CB5
opens, 24 volt ac output to RC4
stops.
Press button to reset breaker.
2 Fuse F2 (See Parts List)
F2 protects the engine wiring system from overload. If F2 opens, the
engine will not crank.
3
3
Fuse F1 (See Parts List)
Remove side panel.
F1 protects the exciter excitation
winding from overload. If F1 opens,
weld and generator power output
stops.
Replace any open fuses. Reinstall
cover before operating unit.
2
1
803 100 / Ref. 801 940 / Ref. 206 580
OM-4410 Page 39
SECTION 8 – TROUBLESHOOTING
8-1. Welding Troubleshooting
Trouble
No weld output.
Remedy
Check control settings.
Check weld connections.
Disconnect equipment from generator power receptacles during start-up.
Place V/A Adjust switch in Panel position, or move switch to Remote position and connect remote
control to Remote receptacle RC4 (see Sections 4-9 and 5-1).
Check and secure connections to Remote receptacle RC4 (see Sections 4-9).
Check fuse F1, and replace if necessary (see Section 7-7).
Have Factory Authorized Service Agent check brushes, slip rings, integrated rectifier SR2, and circuit
boards PC1 and PC2.
Low weld output.
Check control settings.
Place V/A Adjust switch in Panel position, or move switch to Remote position and connect remote
control to Remote receptacle RC4 (see Sections 4-9 and 5-1).
Check and clean air cleaner as necessary (see Section 7-3).
Check engine speed, and adjust if necessary (see Section 7-6).
Have Factory Authorized Service Agent check brushes, slip rings, integrated rectifier SR2, and circuit
boards PC1 and PC2.
See engine manual.
High weld output.
Check control settings.
Check and adjust engine speed (see Section 7-6).
Check for obstructed movement of solenoid linkage (see Section 7-6).
Have Factory Authorized Service Agent check circuit boards PC1 and PC2.
Weld output cannot be adjusted.
Check position of V/A Adjust switch (see Section 5-1).
Have Factory Authorized Service Agent check field current control board PC2.
Erratic weld output.
Check control settings.
Clean and tighten connections both inside and outside unit.
Check and secure lead connections to V/A control.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Use dry, properly stored electrodes.
Check and adjust engine speed (see Section 7-6).
Have Factory Authorized Service Agent check brushes, slip rings, and circuit boards PC1 and PC2.
No remote fine amperage control.
Place V/A Adjust switch in correct position (see Section 5-1).
Check and tighten connections to Remote receptacle RC4 (see Section 4-9).
No power output at Remote
receptacle RC4.
OM-4410 Page 40
Reset circuit breaker CB5 (see Section 7-7).
Trouble
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Welding arc.
Remedy
Use proper size tungsten for welding amperage.
Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Wandering arc – poor control of arc
direction.
Reduce gas flow rate.
Select proper size tungsten. Properly prepare tungsten.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
8-2. Generator Power Troubleshooting
Trouble
No power output.
Remedy
Reset circuit breakers CB1, CB3 and/or CB4 (see Section 6-1).
Check fuse F1, and replace if necessary (see Section 7-7).
Have Factory Authorized Service Agent check brushes, slip rings, integrated rectifier SR2, and circuit
boards PC1 and PC2.
Low power output.
Check and clean air cleaner as necessary (see Section 7-3).
Check engine speed, and adjust if necessary (see Section 7-6).
See engine manual.
High power output.
Check engine speed, and adjust if necessary (see Section 7-6).
Erratic power output.
Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.
Check receptacle wiring and connections.
Check governor according to engine manual.
8-3. Engine Troubleshooting
Trouble
Engine does not crank.
Remedy
Check fuse F2, and replace if open (see Section 7-7).
Check battery voltage.
Check battery connections and tighten if necessary.
Check plug PLG5 and plug PLG8 connections.
Have Factory Authorized Service Agent check Engine Control switch S2.
OM-4410 Page 41
Trouble
Engine does not start.
Remedy
Check fuel level (see Section 4-2).
Open fuel valve (see Section 4-2).
Service primary and secondary fuel filters (see Section 7-5).
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Bleed air from fuel system according to engine manual.
Check fuel solenoid according to engine manual.
Have Factory Authorized Service Agent check glow Plug switch S6, glow plug, and control relay CR3.
Engine starts but stops when Engine
Control switch S2 returns to Run/Idle
position.
Check oil level (see Section 4-2). Engine will not start if oil pressure is too low.
Check coolant level and fan belt (see Section 4-2 and engine manual). Engine will not start if engine
temperature is too high.
Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see Section 7-2).
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine temperature switch S4.
Engine does not stop.
Stop engine by closing fuel valve (see Section 4-2). Adjust shutdown solenoid (see Section 7-6).
Engine stopped during normal
operation.
Check fuel level (see Section 4-2).
Open fuel valve (see Section 4-2).
Check oil level (see Section 4-2). Engine stops if oil pressure is too low.
Check coolant level and fan belt (see Section 4-2 and engine manual). Engine stops if engine temperature is too high.
Bleed air from fuel system according to engine manual.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S5 and engine temperature switch S4.
Battery discharges between uses.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator according to engine manual.
Engine does not return to idle speed
when load is removed with Engine
Control switch in Run/Idle position.
Remove all weld and generator power loads.
Place Process/Contactor switch in Electrode Hot position or turn off remote contactor. The unit will not
return to idle speed when Process/Contactor switch is in a remote position and the remote contactor
is on.
Turn off remote device connected to Remote 14 receptacle RC4 (see Section 4-9).
Check for obstructed movement of solenoid linkage (see Section 7-6).
Have Factory Authorized Service Agent check control relay CR2, current transformer CT1, throttle
solenoid TS1, and circuit boards PC1 and PC2.
Engine does not remain at weld/power
speed when power or weld load is
applied with Engine Control switch in
Run/Idle position.
Check for obstructed movement of solenoid linkage (see Section 7-6).
Have Factory Authorized Service Agent check control relay CR2, current transformer CT1, throttle
solenoid TS1, and circuit boards PC1 and PC2.
OM-4410 Page 42
Trouble
Engine does not remain at idle speed
with Engine Control switch in Speed
Lock position and Speed Lock switch
in Idle position.
Remedy
Check for obstructed movement of solenoid linkage (see Section 7-6).
Have Factory Authorized Service Agent check control relay CR2, Idle Lock switch S7, throttle solenoid TS1, and circuit boards PC1 and PC2
Engine does not remain at weld/power
speed with Engine Control switch in
Speed Lock position and Speed Lock
switch in Run position.
Check for obstructed movement of solenoid linkage (see Section 7-6).
Have Factory Authorized Service Agent check control relay CR2, Idle Lock switch S7, throttle solenoid TS1, and circuit boards PC1 and PC2.
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine (see Section 10 and engine manual).
OM-4410 Page 43
SECTION 9 – ELECTRICAL DIAGRAM
Figure 9-1. Circuit Diagram For Welding Generator
OM-4410 Page 44
208 757-A
OM-4410 Page 45
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
2
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.
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-4410 Page 46
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 A/V range switch in maximum position, A/V control in minimum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe
correct
polarity.
Start engine and run for several
minutes.
3
Set load bank switches and then
adjust generator A/V control so load
equals rated voltage and current of
generator (see nameplate, rating
label, or the specifications section
in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
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
OM-4410 Page 47
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 A/V range switch in maximum position, A/V control in minimum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connectors (polarity is not important).
4
Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
3
5
Start engine and run for several
minutes.
Set grid switches and then adjust
generator A/V control so load
equals rated voltage and current of
the generator (see nameplate, rating label, or the specifications section in this manual).
4
+
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
Check oil level frequently during 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-4410 Page 48
SECTION 11 – GENERATOR POWER GUIDELINES
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
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
aux_pwr 4/02 – 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
3
4
3
1
Use #10 AWG or larger insulated
copper wire.
4
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
GND/PE
OR
2
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
2
Electrically bond generator
frame to vehicle frame by
metal-to-metal contact.
S-0854
OM-4410 Page 49
11-3. Grounding When Supplying Building Systems
1
1
2
2
GND/PE
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Use ground device as stated
in electrical codes.
2
3
ST-800 576-B
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-4410 Page 50
11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
11-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
OM-4410 Page 51
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-4410 Page 52
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
11-8. Power Required To Start Motor
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
1
2
3
4
2
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welding generator amperage output must be at least twice the
motor’s running amperage.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230
HP = 1/4
Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A Starting the motor requires 12.2 amperes.
230
S-0624
11-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-4410 Page 53
11-10. Typical Connections To Supply Standby Power
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
1
2
Customer-supplied equipment is required if
3
generator is to supply standby power during
emergencies or power outages.
Obtain and install correct switch.
Switch rating must be same as or
greater than the branch overcurrent
protection.
1
240 V
4
120/240 Volt
60 Hz
Three-Wire
Service
120 V
5
Neutral
2
Circuit Breakers or Fused
Disconnect Switch
Obtain and install correct circuit
breakers or switch.
120 V
Extension Cord
Select as shown in Section 11-11.
3
6
Generator Connections
Connect terminals or plug of adequate amperage capacity to cord.
Follow all applicable codes and
safety practices.
240 V
120 V
Load
Power Company Service
Meter
Main and Branch Overcurrent
Protection
Double-Pole, Double-Throw
Transfer Switch
120 V
4
7
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.
7
Load Connections
CB
or
Item 4 is not necessary if circuit
protection is already present in
generator power circuit.
F1
5
6
240 V
120/240 Volt
Single-Phase
Three-Wire
Generator Output
Connection
120 V
120 V
Ground
S-0405-A
OM-4410 Page 54
11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
6
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-4410 Page 55
SECTION 12 – PARTS LIST
9
12
11
8
14
13
10
15
7
6
5
22
4
3
23
21
16
2
17
18
19
20
1
92
90 See Figure 12-2
45
70
91
69
72
87
80
74
81
73
88
82
83
79
77
76
84
75
85
89
78
86
71
Figure 12-1. Main Assembly
OM-4410 Page 56
25
29
30
32
33
31
34
37
28
27
24 – See Figure 12–3
36
35
46
26
39
38
59
58
47
42
40
44
43
56
54
41
62
48
55
64
65
50
49
53
63
57
51
52
67
68
60
61
66
803 149
OM-4410 Page 57
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
. . . 1 . . . . . . . . . . . . +182367
. . . . . . . . . . . . . . . . . ♦1+85352
. . . 2 . . . . . . . . . . . . +182366
. . . . . . . . . . . . . . . . . ♦+185353
. . . 3 . . . . . . . . . . . . +206983
. . . . . . . . . . . . . . . . . ♦+206982
. . . . . . . . . . . . . . . . . . ♦163175
. . . . . . . . . . . . . . . . . . ♦163163
. . . . . . . . . . . . . . . . . . ♦206888
. . . . . . . . . . . . . . . . . . ♦152421
. . . . . . . . . . . . . . . . . . ♦163167
. . . . . . . . . . . . . . . . . . ♦163174
. . . . . . . . . . . . . . . . . . ♦152422
. . . . . . . . . . . . . . . . . . ♦163170
. . . . . . . . . . . . . . . . . . ♦152423
. . . 4 . . . . . . . . . . . . . . 205605
. . . 5 . . . . . . . . . . . . . . 200795
. . . 6 . . . . . . . . . . . . . . 192041
. . . 7 . . . . . . . . . . . . . . 181881
. . . 8 . . . . . . . . . . . . . . 147601
. . . 9 . . . . . . . . . . . . . . 205609
. . . 10 . . . . . . . . . . . . . . 183314
. . . 11 . . . . . . . . . . . . +188932
. . . 12 . . . . . . . . . . . . . . 187890
. . . 13 . . . . . . . . . . . . . . 200448
. . . 14 . . . . . . . . . . . . . . 187465
. . . . . . . . . . . . . . . . . . ♦189679
. . . . . . . . . . . . . . . . . . . . 187591
. . . 15 . . . . . . . . . . . . . . 187566
. . . 16 . . . . . . . . . . . . . . 197801
. . . 17 . . . . . . . . . . . . . . 187446
. . . 18 . . . . . . . . . . . . . . 187412
. . . 19 . . . . . . . . . . . . +187510
. . . 20 . . . . . . . . . . . . . . 203509
. . . 21 . . . . . . . . . . . . . . 205736
. . . 22 . . . . . . . . . . . . . . 205734
. . . 23 . . . . . . . . . . . . . . 181789
. . . 24 . . . . . . . . . . Figure 12-3
. . . 25 . . . . . . . . . . . . . . 201921
. . . 26 . . . . . . . . . . . . . . 187639
. . . 27 . . . . . S5 . . . . . 208754
. . . 28 . . . . . . . . . . . . . . 165271
. . . . . . . . . . . . . . . . . . . . 113854
. . . . . . . . . . . . . . . . . . . . 176529
. . . 29 . . . . . . . . . . . . . . 189766
. . . 30 . . . . . . . . . . . . . . 187428
. . . 31 . . . . . . . . . . . . . . 187462
. . . . . . . . . . . . . . . . . . . . 208124
. . . . . . . . . . . . . . . . . . . . 197671
. . . 32 . . . . . . . . . . . . . . 187436
. . . 33 . . . . . . . . . . . . . . 187590
. . . 34 . . . . FS1 . . . . 201923
. . . 35 . . . . TS1 . . . . 208454
. . . 36 . . . . . . . . . . . . . . 198108
. . . 37 . . . . . . . . . . . . . . 198018
. . . 38 . . . . . . . . . . . . . . 187435
. . . 39 . . . . . . . . . . . . . . 187457
. . . . . . . . . . . . . . . . . . . . 187458
. . . 40 . . . . . . . . . . . . . . 187432
. . . 41 . . . . . . . . . . . . . . 187640
. . . 42 . . . . . . . . . . . . . . 187434
OM-4410 Page 58
. . Panel, Side Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Side Rh Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Side Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Side Lh Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cover, Top Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, 250–20x .75 Hex Hd–pln Sst Pln T18–8 302–305 (Stainless) . As Rqd
. . Screw, 250–20x .50 Hex Hd–pln Sst Pln T18–8 302–305 (Stainless) . . . 22
. . Screw, 250–20x2.50 Hex Hd–pln Sst 410 (Stainless) . . . . . . . . . . . . . . . . . 4
. . Screw, 008–32x .50 Rnd Hd–slt Sst Pln (Stainless) . . . . . . . . . . . . . . . . . . 2
. . Washer, Lock .254idx0.489odx.062t Sst Split.250 (Stainless) . . . . . . . . . . 22
. . Washer, Flat .281idx0.625odx.050t Sst (Stainless) . . . . . . . . . . . . . . . . . . 22
. . Washer, Lock .167idx0.293odx.040t Sst Split #8 (Stainless) . . . . . . . . . . . 2
. . Washer, Flat .174idx0.375odx.032t Sst (Stainless) . . . . . . . . . . . . . . . . . . . 2
. . Nut, 008–32 .34hex .13h Sst (Stainless) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Label, Available Power While Welding & True Blue 3y . . . . . . . . . . . . . . . 1
. . Label, Warning General Precautionary Csa . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cap, Tank Screw–on W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Pipe, Exhaust Elbow Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Guard, Belt Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Moving Parts (Wordless) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Label, Warning Steam And Hot Coolant Can Burn . . . . . . . . . . . . . . . . . . . 1
. . Panel, Rear Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Rear Upper Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spacer, Al .250 Id X .500 Od X .750 (radiator) . . . . . . . . . . . . . . . . . . . . . . 4
. . Bracket, Mtg Air Cleaner Inlet Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Radiator, W/14# Cap 2 Row Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Fan, Engine Cooling 12.000 Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Guard, Fan Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Caution Exhaust Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Upright, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Seal, Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Engine, Kubota Dsl Elec D722–mi–b W/Components (consisting of) . . . 1
. . . . Adapter, Oil Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Switch, Pressure Oil 11psi NC Cont Frict Term . . . . . . . . . . . . . . . . . . . . 1
. . . . Valve, Oil Drain 3/8–18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Hose, Sae .500 Id X .780 Od Xcoil (Oil Drain) . . . . . . . . . . . . . . . . . . . . . 1
. . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt (Oil Drain) . . . . . . . . . . . 1
. . . . Muffler Gasket, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Muffler, Exhaust Engine Kubota D722 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bottle, Overflow W/Cap & Hose (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . Cap w/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Label, Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Hose, Radiator Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Guard, Belt Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Solenoid, Fuel/Shutdown W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Solenoid, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bracket, Mounting Throttle Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Linkage, Throttle Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Hose, Radiator Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bracket, Mtg Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bracket, Mtg Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Clamp, Air Cleaner W/Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Hose, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . . 43 . . . . . . . . . . . . . . 187431 . . . . Air Cleaner, Intake Dry Straight Outlet Type (consisting of) . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *187441 . . . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ♦*202102 . . . . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 44 . . . . . . . . . . . . . *187442 . . . . Element, Fuel Filter (engine-mounted) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 45 . . . . . . . . . . . . . . 066113 . . . . Filter, Fuel Inline .250 (included with engine) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 187444 . . . . Bracket, Mtg Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *187443 . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . *187459 . . . . Belt, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 187819 . . . . Injector Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . GLOW PLUG . 187820 . . . . Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . . . . . 187429 . . Spacer, Fan (not included w/engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 200064 . . Manifold, Exhaust Kubota 722 (not included w/engine) . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 200065 . . Gasket, Ex. Manifold To Head Kabota 722 (not included w/engine) . . . .
. . . 47 . . . . . . . . . . . . . . 187589 . . Hose, Air Cleaner Intake (not included w/engine) . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ♦*206421 . . Filter Kit, Kubota 722 (includes air cleaner element, oil and fuel filters) . .
. . . 48 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . .
. . . 49 . . . . . . . . . . . . +201174 . . Door, Access Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . . . 182935 . . Hold Down, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 51 . . . BATTERY . . . 168037 . . Battery, Stor 12v 430 Crk 75 Rsv Gp 58 Dry . . . . . . . . . . . . . . . . . . . . . . . .
. . . 52 . . . . . . . . . . . . . . 187616 . . Cable, Bat Pos 32.000 No 4 Awg W/Clamp & .343 Rng . . . . . . . . . . . . . .
. . . 53 . . . . . . . . . . . . . . 167730 . . Cable, Bat Neg 29.000 No 4 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 165600 . . Cable, Bat Neg 18.500 6ga W/.250 Rng & .375 Rng . . . . . . . . . . . . . . . . .
. . . 54 . . . . . . . . . . . . . . 187550 . . Mount, Engine 60 Duro Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 55 . . . . . . . . . . . . . . 187454 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 204741 . . Harness, Wrg Engine (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 56 . . VOLT REG . . 187821 . . . . Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG32 . . . 204678 . . . . Connector, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 57 . . . . CR3 . . . . 155309 . . . . Contactor, Solenoid 12vdc Continuous 400a Inrush . . . . . . . . . . . . . . . .
. . . 58 . . . . . . . . . . . . . . 206549 . . . . Holder, Fuse (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 59 . . . . . F2 . . . . *208914 . . . . . . Fuse, Mintr Cer Slo–blo 20. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . PLG31, PLG32 092670 . . . . Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 192167 . . . . Seal, Wire Univ 3p/S 1row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG5 . . . . 135134 . . . . Conn, Rect Univ 084 9p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 187651 . . . . Seal,Wire Univ 9p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 60 . . . . . . . . . . . . +187464 . . Pan, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 61 . . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 62 . . . . . . . . . . . . . . 204485 . . Panel, Rear Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 63 . . . . . . . . . . . . . . 192362 . . Bracket, Mtg Nyl 1/2 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 64 . . . . . . . . . . . . . . 187551 . . Mount, Generator 70 Duro Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 65 . . . . . . . . . . . . . . 187455 . . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 66 . . . . . . . . . . . . . . 181057 . . Cover, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 67 . . . . . . . . . . . . . . 187588 . . Label, Engine Maintenance Kubota D722 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 68 . . . . . . . . . . . . . . 197930 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 134834 . . Hose, Sae .187 Id X .410 Od Xcoil (fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 134835 . . Hose, Sae .312 Id X .560 Od Xcoil (fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 69 . . . . . . . . . . . . . . 187479 . . Tank, Fuel 10.0 Gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 182922 . . . . Bushing, Tank Fuel 1.210id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 182925 . . . . Gauge, Fuel Float Type 5.50 Float Travel . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 187586 . . . . Ftg, Stand Pipe .312 X 7.375 Lg 90 Degree . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 187501 . . . . Ftg, Stand Pipe .187 X 7.375 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 70 . . . . . . . . . . . . . . 172707 . . Seal, Fuel Hose Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 71 . . . . DC-Z . . . . 202337 . . Stabilizer, Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 72 . . . . PC1 . . . . 209128 . . Circuit Card Assy, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 73 . . CR1, CR2 . . 173069 . . Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg (Included In
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Wiring Harness, See Figure 12-2) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 74 . . . . . . . . . . . . . . 204148 . . Bracket, Mtg PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 75 . . . . . . . . . . . . . . 204166 . . Bracket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 202331 . . Gasket, Capacitor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 76 . . . . . . . . . . . . . . 172731 . . Holder, Fuse Mintr .250 X 1.250 Clip Anti–pivot . . . . . . . . . . . . . . . . . . . . .
. . . 77 . . . . . F1 . . . . *169296 . . Fuse, Mintr Gl 25. Amp 125 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 78 . . . . SR2 . . . . 200759 . . Rectifier, Integ Bridge 35. Amp 600v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 79 . . . . . . . . . . . . . . 165437 . . Clip, Snap In .472 Bundle .250hole .020–.197 Thk . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
4
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
OM-4410 Page 59
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . . 80 . . . . . . . . . . . . . . 115440
. . . 81 . . . . . . . . . . . . . . 004214
. . . 82 . . . . . . . . . . . . . . 200263
. . . 83 . . . . . . . . . . . . . . 204769
. . . 84 . . . . . 1T . . . . . 172661
. . . . . . . . . . . . . . . . . . . . 173734
. . . 85 . . . . C16 . . . . 199979
. . . 86 . . . . C25 . . . . 176007
. . . 87 . . . . . R1 . . . . . 188067
. . . 88 . . . . CT1 . . . . 206369
. . . 89 . . . . . . . . . . . . . . 180628
. . . 90 . . . . . . . . . . Figure 12-2
. . . 91 . . . . SR1 . . . . 202222
. . . 92 . . . . . . . . . . . . . . 202339
. . . . . . . . . . . . . . . . . . . . 205646
♦ Optional
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Stand–off, No 6–32 X .687 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . .
Bushing, Snap–in Nyl 1.625 Id X 2.000 Mtg Hole . . . . . . . . . . . . . . . . . . . .
Label, Warning Electric Shock Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Term Mkg Stator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, Elctlt 1500 Uf 75 Vdc Can 1.40 Dia . . . . . . . . . . . . . . . . . . . . . .
Capacitor, Elctlt 1200 Uf 300 Vdc Can 1.37 Dia . . . . . . . . . . . . . . . . . . . . .
Resistor, Ww Fxd 100 W 200 Ohm W/Clips . . . . . . . . . . . . . . . . . . . . . . . .
Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier, Si 3ph 300 Amp 400 Piv 100% Duty Cycle . . . . . . . . . . . . . . . . .
Baffle, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
1
1
1
1
2
1
1
1
1
1
1
1
1
1
*
Recommended Spare Parts.
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 205 646.
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-4410 Page 60
Hardware is common and
not available unless listed.
7
6
4
5
3
2
8
9
1
10
12
11
13
38
37
36
35
14
34
15
33
16
17
32
18
31
30
20
19
21
24
27
26
25
23
22
28
29
803 150
Figure 12-2. Panel, Front w/Components
OM-4410 Page 61
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 90)
. . . 1 . . . . . . . . . . . . . . 206854 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . 073756 . . Stand–off, No 6–32 X .625 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 203401 . . Stand–off Support, Pc Card .187 Dia W/P&l .625 . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . PC2 . . . . 204588 . . Circuit Card Assy, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 206794 . . Bag, Protective Anti Static 5:00x12:00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . S1 . . . . . 204641 . . Switch, Changeover Assy W/Leads (consisting of) . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . . 187189 . . . . Bracket, Mtg Shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . LEM . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 202381 . . Harness, Remote Control 14pin (consisting of) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG23 . . . 115093 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . RC4 . . . . 143976 . . . . Rcpt W/Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 202884 . . Harness, Switch Control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG20 . . . 131198 . . . . Conn, Rect Mini 045 3skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . S3 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On–none–on Spd Term Chr . . . . . . . . . . .
. . . 10 . . . . CB5 . . . . 083432 . . Circuit Breaker, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . S2 . . . . . 176606 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . RC2, RC3 . . . 141432 . . Rcpt, Str Dx Grd 2p3w 20a 125v *5–20r . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ♦151981 . . Rcpt,Str Dx Grd 2p3w 15/20a 125v *5–20r GFCI . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . CB3, CB4 . . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . 203026 . . Circuit Breaker, Man Reset 2p 50a 240vac Screw–90 . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 206626 . . Harness, Wrg Ignition (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . CR1, CR2 . . . 173069 . . . . Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg (Located On
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Mounting Bracket, See Figure 12-1) . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC5 . . . . 135133 . . . . Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . .
. . . 15 . . . . . S7 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On–none–on Spd Term Chr . . . . . . . . . . .
. . . 16 . . . . . S6 . . . . . 021467 . . . . Switch, Tgl Spst 3a 250v Off–none–(On) Spd Term . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG7 . . . . 168165 . . . . Conn, Rect Univ 084 3p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . .
. . . . . . . . . PLG15 . . . 113751 . . . . Conn, Rect Mini 045 8skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG19 . . . 113752 . . . . Conn, Rect Mini 045 10skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 202660 . . . . Conn, Push 4 Wire 12–16strnd 12–18sld 16–22tinstrnd . . . . . . . . . . . .
. . . . . . . . . . PLG8 . . . . 177859 . . . . Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . PC5 . . . . 148030 . . Circuit Card Assy, Filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . PC3 . . . . 148021 . . Circuit Card Assy, Filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 134201 . . Stand–off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . .
. . . 19 . . . PL1, PL2 . . . 206879 . . Light, Ind Amber Lens 12v Snap–in Mtg .500 Mtg Hol . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . 119014 . . Lever, Switch Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . 129524 . . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . 099255 . . Terminal, Pwr Output Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . 601836 . . Nut, 250–20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . 602207 . . Washer, Lock .255idx0.489odx.062t Stl Pld Split.250 . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . 083030 . . Stud, Brs .250–20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . 188039 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . 203016 . . Boot, Circuit Breaker 2 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . 159921 . . Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . RC1 . . . . 182954 . . Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14–50 . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . HM . . . . . 145247 . . Meter, Hour 12–24vdc 1.25 X 2.12 Rect . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . 097924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . 115493 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 204642 . . Receptacles, W/Leads (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC29 . . . . 113751 . . . . Conn, Rect Mini 045 8skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG6 . . . . 204640 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC30 . . . . 136924 . . . . Conn, Rect Comm 093 2p/S 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . 206 580 . . Nameplate, screened (order by model and serial number) . . . . . . . . . . . . .
OM-4410 Page 62
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
6
2
1
1
3
1
1
2
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-2. Panel, Front w/Components (Continued)
....................
. . . . . . . . . PLG13 . . .
. . . . . . . PLG12, PLG27 . .
. . . . . . . . . PLG21 . . .
....................
. . . . . . . . . . RC9 . . . .
. . . . . . . . . PLG25 . . .
. . . . . . . . . . RC7 . . . .
....................
. . . . . . . . . PLG18 . . .
♦Optional
+
202883
114655
117037
113750
206534
136924
113752
130204
204773
131198
. . Harness, Control Power Board Interconnecting (consisting of) . . . . . . . . .
. . . . Conn, Rect Mini 045 6skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Mini 045 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . Harness, Wrg Interconnecting (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Comm 093 2p/S 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Mini 045 10skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . Plug, W/Leads (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Mini 045 3skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 205 646.
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-4410 Page 63
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-3. Generator (Figure 12-1 Item 24)
. . . 1 . . . STATOR . +207281
. . . 2 . . . . . . . . . . . . . . 182092
. . . 3 . . . ROTOR . . . 204274
. . . 4 . . . . . . . . . . . . . . 181143
. . . 5 . . . . . . . . . . . . . . 187493
. . . 6 . . . . . . . . . . . . . . 186365
. . . 7 . . . . . . . . . . . . . . 170861
. . . 8 . . . . . . . . . . . . . . 205725
. . . . . . . . . . . . . . . . . . . . 203387
. . . . . . . . . PLG17 . . . 202 511
. . . 9 . . . . . . . . . . . . . . 010910
. . . 10 . . . . . . . . . . . . . . 202349
+
. . Stator, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning Moving Parts Can Cause Serious Etc . . . . . . . . . . . . . . . . 2
. . Rotor, Generator (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . 1
. . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Adapter, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Stud, Stl .375–16 X 17.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Harness, Wrg Brushholder (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Univ 084 6p/S 3row Plug Cable Lkg (Service Kit) . . . . . . . . 1
. . Nut, .375-16 .56 Hex X .46h Stl Pld Elastic Stop . . . . . . . . . . . . . . . . . . . . . 4
. . Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 205 646.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Hardware is common and
6
not available unless listed.
3
5
4
2
1
10
7
8
9
803 151
Figure 12-3. Generator
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 205 646.
*Recommended Spare Parts.
OM-4410 Page 64
Effective January 1, 2001
(Equipment with a serial number preface of “LB” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts – 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 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.
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 10/01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
 2002 Miller Electric Mfg. Co.
1/02
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