Miller | LA340225 | Owner Manual | Miller TRAILBLAZERPRO 350 User manual

Miller TRAILBLAZERPRO 350 User manual
OM-4401
198 521E
February 2001
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
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 Pro 350
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
Miller is the first welding help you figure out what the problem is. The
equipment manufacturer in parts list will then help you to decide which
the U.S.A. to be registered to
the ISO 9001 Quality System exact part you may need to fix the problem.
Standard.
Warranty and service information for your
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 or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
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.
CALIFORNIA
Proposition 65
Warning
Diesel engine exhaust
and some of its constituents are known to
the State of California to
cause cancer, birth
defects, and 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. AC Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. CC/DC Stick Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. CC TIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. DC/CV MIG/TIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Adding Coolant To Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Selecting Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Remote 14 Receptacle RC1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Description Of Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Operating Unit At Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Auxiliary Power Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . .
SECTION 7 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Servicing Engine Lubrication And Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 – RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 – AUXILIARY POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
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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-4401 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.
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.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Engine Hazards
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-4401 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.
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 ACID can BURN SKIN and
EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
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.
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.
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-4401 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-4401 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-4401 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-4401 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-4401 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-4401 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
CC
Stop Engine
Fast
(Run, Weld/Power)
Fast/Slow
(Run/Idle)
Slow (Idle)
Start Engine
Panel/Local
Temperature
Fuel
Engine Oil
High Temperature
Check Valve
Clearance
Battery (Engine)
Engine
Glow Plug
MIG (GMAW),
Wire
Stick (SMAW)
TIG (GTAW)
Circuit Breaker
Constant Voltage
Electrode
Positive
Electrode Negative
Positive
Negative
Alternating Current
(AC)
Output
Time
Hours
Seconds
Protective Earth
(Ground)
Work Connection
Read Operator’s
Manual
CV
Constant Current
h
Do not switch while
welding
14
A
s
Remote 14
Receptacle
Amperes
V
Volts
SECTION 3 – SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
Rated
Welding
Output At
Weld
Speed
Rated
Welding
Output At
Idle Speed
Maximum
Open-Circuit
Voltage
Amperage
Range In
CC Mode
CC/AC
200 A,
25 V, 60%
Duty Cycle
––
75
40 – 225 A
CC/DC
350 A,
28 V, 60%
Duty Cycle
180 A, 28
V, 100%
Duty Cycle
80
20 – 350 A
CV/DC
300 A,
32 V, 100%
Duty Cycle
––
50
––
Voltage
Range In
CV Mode
Auxiliary
Power Rating
10 – 34 V
Peak: 12 kVA/kW
Continuous:
Single-Phase,
10 kVA/kW
50/41.6 A,
120/240 V AC,
60 Hz
Fuel
Capacity
Engine
13 gal(49 L)
Tank
Kubota DH905
Water-Cooled,
Three-Cylinder,
Four-Cycle,
26 HP Diesel
Engine
OM-4401 Page 9
3-2. Dimensions, Weights, and Operating Angles
Dimensions
Height
36 in (914 mm)
(to top of exhaust)
Width
24 in (610 mm)
A
B
C
Do not exceed tilt angles or engine could
be damaged or unit could tip.
D
Depth
59-1/2 in (1511 mm)
A
23-5/8 in (600 mm)
B
21-1/2 in (546 mm)
C
1 in (25 mm)
D
15-5/8 in (397 mm)
E
26-3/8 in (679 mm)
F
58-3/4 in (1492 mm)
G
13/32 in (10 mm) Dia.
G
4 Holes
Do not move or operate unit where it could
tip.
E
F
20°
20°
20°
20°
Weight
1030 lb (467 kg)
Front Panel End
800 426
3-3. Fuel Consumption
7.57
1.70
2.00
6.62
1.46
1.75
5.67
1.25
1.50
4.73
1.04
1.25
3.78
0.83
1.00
2.84
0.62
0.75
1.98
0.40
0.50
0.95
0.21
0.25
DC STICK/AUX POWER
(HIGHSPEED)
DC STICK
(LOW SPEED)
IDLE
U.S. GAL./HR.
IMP. GAL./HR.
LITERS/HR.
0
0
0
50
1
100
2
150
4
200
6
250
8
300
10
350
12
400
DC WELD AMPERES AT 100% DUTY CYCLE
POWER KVA AT 100% DUTY CYCLE
200 334
OM-4401 Page 10
3-4. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
Exceeding duty cycle can
damage unit and void
warranty.
WELD AMPERES
400
DC
350
300
250
AC
200
150
100
0
10
20
30
40
50
60
70
80
90 100
% DUTY CYCLE
60% Duty Cycle at 350 Amperes DC
6 Minutes Welding
4 Minutes Resting
198 919
3-5. AC Auxiliary Power Curve
The ac power curve shows the auxiliary power in amperes available at
the 120 and 240 volt receptacles.
150 300
12 kW
AC VOLTS
125 250
100 200
75 150
50 100
25
50
0
0
0
10
0
20
20 30 40 50 60 70 80 90
AC AMPERES IN 240V MODE
40 60 80 100 120 140 160 180
AC AMPERES IN 120V MODE
200 268
OM-4401 Page 11
3-6. CC/DC Stick Volt-Ampere Curves
A. CC/DC (Stick) Mode
100
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
DC VOLTS
80
60
40
20
0
0
50
100 150 200 250 300 350 400 450 500
DC AMPERES
B. CC/DC Stick Mode (Idle Speed)
100
DC VOLTS
80
60
40
20
0
0
50
100 150 200 250 300 350 400 450 500
DC AMPERES
200 269 / 200 270
OM-4401 Page 12
3-7. CC TIG Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
A. CC/AC TIG Mode
100
AC VOLTS
80
60
40
20
0
0
50
100 150 200 250 300 350 400 450 500
AC AMPERES
B. CC/DC TIG Mode
100
DC VOLTS
80
60
40
20
0
0
50
100 150 200 250 300 350 400 450 500
DC AMPERES
200 271 / 200 272
OM-4401 Page 13
3-8. DC/CV MIG/TIG Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
100
DC VOLTS
80
60
40
20
0
0
100
200
300
400
500
DC AMPERES
600
700
200 273
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
Do not lift unit from end.
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
OR
Grounding
Location
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
18 in
(460 mm)
18 in
(460 mm)
Always securely fasten
welding generator onto
transport vehicle or trailer
and comply with all DOT and
other applicable codes.
1
2
3
3
1
GND/PE
4
4
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
If 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. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
OM-4401 Page 14
4-2. Engine Prestart Checks
Remove air bleed screw
when filling radiator. See
Section 4-3.
Full
Check radiator coolant level when fluid is low in recovery tank.
Full
1/2 in
(13 mm)
Capacity
w/Overflow Tank
6.4 qt (6 L)
Full
Diesel
Full
Ref. 802 579-A
Check all fluids daily. Engine must be cold
and on a level surface. Unit is shipped with
10W30 engine oil.
Engine stops if oil pressure is too low or engine temperature is too high.
This unit has a low oil pressure shut-
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual. If
unburned fuel and oil collect in exhaust pipe
during run-in, see Section 9.
Fuel
Do not use gasoline. Gasoline will
damage engine.
Add fresh diesel fuel before starting engine
the first time (see maintenance label for
specifications). Fill fuel tank up to 1/2 in. (13
mm) from top to allow room for expansion.
Do not run out of fuel or air enters fuel system and causes starting problems. See engine manual to bleed air from fuel system.
Oil
After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Engine may use oil and wetstacking
may occur during run-in period.
Check oil several times daily during
run-in.
Coolant
Check coolant level in recovery tank before
starting unit the first time. Add coolant if
coolant is below bottom of radiator filler neck
(see Section 4-3 for radiator filling instructions.
Check coolant in recovery tank daily. If coolant is below Full level, add coolant until coolant level in tank is between Full and Low levels. If recovery tank coolant level was low,
also check coolant level in radiator (see
Section 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 and free
of dirt.
Incorrect engine temperature can
damage engine. Do not run engine
without a properly working thermostat and radiator cap.
To improve cold weather starting:
Keep battery in good condition. Store
battery in warm area off concrete
surface.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel
information.
Use correct grade oil for cold weather.
OM-4401 Page 15
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:
1
1 Radiator Air Bleed Screw
Remove radiator air bleed screw.
Add coolant to radiator until coolant
is at bottom of filler neck. This ensures all air is purged from the system.
Full
Reinstall screw and radiator cap.
Check coolant level in recovery
tank (see Section 4-2).
Capacity
w/Overflow Tank
6.4 qt (6 L)
Engine coolant is a mixture of water
and ethylene glycol base antifreeze. A solution of 50% antifreeze
and 50% water must be used in this
engine. Do not use 100% antifreeze
or severe damage will occur.
Tools Needed:
Ref. 802 579-A
4-4. Connecting The Battery
Connect
negative (–)
cable last.
–
+
Tools Needed:
3/8, 1/2 in
Ref. 198 834-A / Ref. 802 579-A / Ref. S-0756-D
OM-4401 Page 16
4-5. Installing Exhaust Pipe
Point exhaust pipe in desired
direction but always away from
front panel and direction of
travel.
Tools Needed:
1/2 in
802 173-C / Ref. 198 834-A
4-6. Connecting To Weld Output Terminals
Do not connect to CC and CV
terminals at the same time.
1
2
3
Work Weld Output Terminal
CC (Stick/TIG) Weld Output
Terminal
CV (MIG) Weld Output
Terminal
For MIG welding, connect work
cable to Work terminal and wire
feeder cable to CV (MIG) terminal.
For Stick/TIG welding, connect
work cable to Work terminal and
electrode holder cable to CC (Stick/
TIG) terminal.
2
3
1
802 580-A / 198 834-A
OM-4401 Page 17
4-7. Selecting Weld Cable Sizes
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
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.
* This
10 – 100% Duty Cycle
chart is a 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.
4-8. Remote 14 Receptacle RC1 Information
NOTE
Engine runs at weld/power speed whenever a device connected to the remote 14
receptacle is running.
Socket*
Socket Information
A
24 volts ac. Protected by circuit breaker CB5.
B
Contact closure to A completes 24 volts ac
contactor control circuit.
I
115 volts ac. Protected by circuit breaker CB6.
J
Contact closure to I completes 115 volts ac
contactor control circuit.
C
Output to remote control; 0 to +10 volts dc.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control. Voltage is dependent on front panel V/A Adjustment control setting.
G
Circuit common for 24 and 115 volts ac circuits.
K
Chassis common.
24 VOLTS AC
A
B
K
J
I
115 VOLTS AC
H
C L N
D M
G
E F
REMOTE
OUTPUT
CONTROL
GND
*The remaining sockets are not used.
OM-4401 Page 18
Notes
OM-4401 Page 19
SECTION 5 – OPERATING WELDING GENERATOR
5-1. Controls (See Section 5-2)
2
3
4
9
8
7
6
5
1
14
13
10
11
12
15
198 834-A-A / Ref. 802 579-A
OM-4401 Page 20
5-2. Description Of Controls (See Section 5-1)
Use switch to select AC weld output or polarity
of DC weld output.
14 Engine Speed Switch
Use switch to select engine speed.
Place switch in Idle position to lock engine at
idle speed during start-up, and to CC weld at
idle speed (up to 180 A). See Section 5-4 for
information on operating at idle speed.
In Run/Idle position, engine runs at idle speed
at no load and weld/power speed under load.
In Run position, engine runs at weld/power
speed.
10 Process/Contactor Switch
Place switch in Run or Run/Idle position
Engine Lights
8
1
Meter displays weld voltage at the weld terminals, but not necessarily the welding arc due
to resistance of cables and connections.
Battery Charging Light
Light goes on if engine alternator is not charging battery. Engine continues to run.
Stop engine and fix trouble if Battery
Charging light goes on.
2
Stop engine and fix trouble if Engine
Temperature light goes on.
Engine Oil Pressure Light
Light goes on and engine stops if oil pressure
is too low. Light goes on momentarily during
start-up but goes out when engine reaches
normal oil pressure.
Stop engine and fix trouble if Engine
Oil Pressure light stays on after startup.
4
DC Polarity/AC Selector Switch
Do not switch under load.
Engine Temperature Light
Light goes on and engine stops if engine temperature is too high.
3
9
Voltmeter (Optional)
Glow Plug Light
LIght is not active on this model.
See Section 5-3 for Process/Contactor switch
information.
11 V/A (Voltage/Amperage) Adjust Switch
And Remote 14 Receptacle
For front panel control, place switch in Panel
position and use the V/A Adjustment control.
For remote control, make connections to Remote 14 receptacle, and place switch in Remote position (see Sections 4-8 and 5-5). The
value selected on V/A Adjustment control is
the maximum available at the remote.
Glow plug warms in about six seconds and engine can be started (see starting instructions
following).
Set V/A Adjustment control (item12) to
Do not use glow plug longer than 20
seconds.
12 V/A (Voltage/Amperage) Adjustment
Control
Engine Gauges
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage.
With Process/Contactor switch in any MIG
position, use control to adjust voltage.
max for MIG welding.
when using auxiliary power.
Place switch in Run position to operate
most GMAW equipment.
To Start:
Above 325 F: turn Engine Speed switch to Idle
and Engine Control switch to Start. Release
Engine Control switch when engine starts and
Engine Oil Pressure light goes out.
If engine does not start, let engine come
to a complete stop before attempting restart.
Below 325 F: turn Engine Speed switch to
Idle. Turn Engine Control switch to Glow Plug
position for about six seconds, and then turn
Engine Control switch to Start. Release switch
when engine starts and Engine Oil Pressure
light goes out. Do not crank engine while engine is turning.
If engine does not start, let engine come
Use gauge to check fuel level.
Engine Starting Controls
to a complete stop before attempting restart.
To Stop: turn Engine Control switch to Off
position.
Weld Controls
13 Engine Control Switch
Push engine stop lever to stop engine if
5
Engine Hour Meter
6
Fuel Gauge
7
Ammeter (Optional)
Meter displays weld amperage at the weld output terminals, but not necessarily the welding
arc due to resistance of cables and connections.
Use switch to start engine, stop engine, and
operate glow plug for cold weather starting.
Glow plug warms in about six seconds and engine can then be started (see starting instructions following).
Engine Control switch does not work (see
item 15).
15 Engine Stop Lever
Use lever to stop engine if Engine Control
switch does not work.
OM-4401 Page 21
5-3. Process/Contactor Switch
1
1
Process/Contactor Switch
Weld output terminals are energized when Process/Contactor switch is in any Electrode Hot position and the engine is running.
Use switch to select weld process
and weld output on/off control (see
table below and Section 5-5).
Place switch in Remote positions to
turn weld output on and off with a device connected to the remote 14 receptacle.
Place switch in Electrode Hot positions for weld output to be on whenever the engine is running.
Use Stick position for air carbon arc
(CAC-A) cutting and gouging.
198 834-A-A / 802 580-A
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Remote – TIG
GTAW With HF Unit, Pulsing Device,
Or Remote Control
At Remote 14 Receptacle
Remote – Stick
Stick (SMAW) With Remote On/Off
At Remote 14 Receptacle
Remote – MIG
MIG (GMAW)
At Remote 14 Receptacle
Electrode Hot – MIG
MIG (GMAW)
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
5-4. Operating Unit At Idle Speed
1
Engine Speed Switch
Use Idle speed when:
1
Starting
Stick welding at up to 180 A.
To weld above 180 A, place Engine
Speed switch in Run or Run/Idle
position.
When Stick welding at idle speed, the
front panel Voltage/Amperage control
setting is accurate up to 180 A. Above
180 A, weld output is slightly less than
Voltage/Amperage control setting.
Place switch in Run or Run/Idle position when using auxiliary power.
Place switch in Run position to operate most GMAW equipment.
198 834-A / 802 580-A
OM-4401 Page 22
5-5. Remote Voltage/Amperage Control
1
Remote 14 Receptacle RC1
Connect optional remote control to
RC1 (see Section 4-8).
1
In Example:
Process = Stick (Using Remote On/Off)
Min = 40 A DC
Max = 180 A DC
Example: Combination Remote Amperage Control (Stick)
Max (180 A DC)
Min (40 A DC)
Set V/A
Adjust Switch
Set Remote
Process
Set Polarity
Set V/A Control
Adjust Optional Remote Control
In Example:
Process = MIG
Min = 12 V DC
Max = About 25 V DC
Example: Combination Remote Voltage Control (MIG)
12 V
Set V/A
Adjust Switch
Set Remote
Process
Set Polarity
Set V/A Control
To Max
25 V
Adjust Voltage
0774 / Ref. 198 834-A
OM-4401 Page 23
SECTION 6 – OPERATING AUXILIARY EQUIPMENT
6-1. Auxiliary Power Receptacles And Circuit Breakers
If unit does not have GFCI
receptacles, use GFCI-protected extension cord.
Auxiliary
power decreases as
weld current increases.
1
2
3
1
240 V 50 A AC Receptacle
RC3
RC3 supplies 60 Hz single-phase
power at weld/power speed. Maximum continuous output is 10 kVA/
kW.
2
120 V 20 A AC GFCI Duplex
Receptacle GFCI-4
3
120 V 20 A AC GFCI Duplex
Receptacle GFCI-5
GFCI-4 and GFCI-5 supply 60 Hz
single-phase power at weld/power
speed. Maximum output from
GFCI-4 or GFCI-5 is 2.4 kVA/kW.
4
4
Circuit Breaker CB1
CB1 protects RC3 from overload. If
CB1 opens, RC3 and one of the 120
volt receptacles does not work.
5
Circuit Breaker CB3
6
Circuit Breaker CB4
CB3 protects GFCI-4 and CB4 protects GFCI-5 from overload. If a circuit breaker opens, the receptacle
does not work.
Move switch (CB1) or press but-
ton (CB3, CB4) to reset circuit
breaker. If breaker continues to
open, contact Factory Authorized Service Agent.
5
6
Simultaneous Welding And Auxiliary Power
Output
Weld Current
Amperes
0
50
100
150
200
250
300
350
Watts
12000
10900
9100
7600
6400
4000
1900
1000
120 V
Receptacle
Amperes
240 V
Receptacle
Amperes
50
50
50
50
50
34
16
8
50
46
38
32
27
17
8
4
Combined output of all receptacles
limited to 10 kVA/kW rating of the
generator.
EXAMPLE: If 19 A is drawn from
each 120 V duplex receptacle, only
23 A is available at the 240 V
receptacle:
2 x (120 V x 19 A) + (240 V x 23 A) =
10 kVA/kW
Ref. ST-198 834-A
OM-4401 Page 24
6-2. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
1
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
3
4
1
Tools Needed:
Plug Wired for 120/240 V,
3-Wire Load
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
120V
120V
5
240V
6
2
3
4
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
Strip cord jacket back enough to
separate conductors.
Strip conductors enough to make
good contact with plug terminals.
Make plug connections and reinstall outer shell and cord grip.
240V
6
5
Tighten assembly screws onto
shell. Do not overtighten.
Plug1 7/99 – ST-120 813-D
Notes
OM-4401 Page 25
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.
Stop engine before maintaining.
Recycle
engine
fluids.
See also Engine Manual and Maintenance Label.
Service engine more often if used in severe conditions.
*
To be done by Factory Authorized Service Agent.
8h
Full
Wipe Up
Spills.
Check Fluid
Levels. See
Section 4-2.
Drain Water From
Fuel System. See
Section 7-5.
FUEL
WATER
Recovery Tank
20 h
Check and clean optional
spark arrestor screen.
See Section 7-3.
50 h
Clean and
tighten weld
terminals.
Check fuel lines
and
connections.
See Section 7-5.
100 h
Check air cleaner hoses
for cracks and loose
clamps.
Service air filter element.
See Section 7-4.
Clean and
tighten battery
connections.
5/16 in.
(8 mm)
Check belt tension.
200 h
Change oil filter.
Section
7-5
maintenance label.
Change oil. See Section 7-5
and maintenance label.
Replace primary
(in-line) fuel filter.
See Section 7-5.
Check radiator
hoses
and
clamps.
Replace unreadable
labels.
400 h
Replace secondary
fuel filter. See
Section 7-5.
OM-4401 Page 26
See
and
500 h
Replace fan belt.
Drain sludge from
fuel
tank.
Flush radiator.
FUEL
SLUDGE
Repair or replace
cracked cables.
800 h
Check valve
clearance.*
1000 h
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
OR
Service welding generator
brushes and slip rings. Service
more often in dirty conditions.*
2000 h
Replace fuel
lines
and
clamps. See
Section 7-5.
Replace
radiator
coolant and hoses.
See Section 7-6.
7-2. Maintenance Label
OM-4401 Page 27
7-3. Servicing Optional Spark Arrestor
Stop engine and let cool.
1
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
Start engine and run several minutes to blow out cleanout hole. If
nothing blows out of hole, briefly
cover end of exhaust pipe with fireproof material.
Stop engine and let cool.
Reinstall cleanout plug.
1
Tools Needed:
1/4 in
802 656
Notes
OM-4401 Page 28
7-4. Servicing Air Cleaner
Stop engine.
1
2
3
Do not run engine without air
cleaner or with dirty element. Engine damage caused by using a
damaged element is not covered
by the warranty.
4
The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
5
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
Keep nozzle
2 in (51 mm)
from element.
1
Housing
2
Safety Element (Optional)
3
Primary Element
4
Dust Cap
5
Dust Ejector
To clean air filter:
Blow
Inspect
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 – ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-4401 Page 29
7-5. Servicing Engine Lubrication And Fuel Systems
4
FLOW
5
4
6
1
7
3
8
Tools Needed:
2
9/16 in
Ref. 802 579-A / Ref. 198 834-A / S-0842
Stop engine and let cool.
1
Oil Filter
2
Oil Drain Valve
3
1/2 ID Hose
4
Fuel Line
5
Primary (In-Line) Fuel Filter
6
Secondary (Canister) Fuel Filter
7
Petcock
8
Fuel Tank Sludge Drain
base. Change engine oil and filter according to instructions in engine manual.
Replace secondary fuel filter according to
engine manual.
Close valve and valve cap before adding oil and running engine.
Replace fuel lines if cracked or worn.
Fill crankcase with new oil to full mark on
dipstick (see Section 4-2).
After servicing, start engine and
check for fuel leaks.
To drain water from fuel system:
Open secondary fuel filter petcock and
drain water into metal container. Close petcock when water-free fuel flows.
To change oil and filter:
To change fuel filters:
Pull oil drain hose through access hole in
Install new primary fuel filter as shown.
OM-4401 Page 30
Wipe up any spilled fuel.
Stop engine, tighten connections as
necessary, and wipe up fuel.
To drain sludge from fuel tank:
Put metal container under drain, and remove sludge drain plug. Reinstall plug
when done.
7-6. Servicing Engine Cooling System
Stop engine and let cool.
1
Radiator Draincock
2
Radiator Cap
3
Radiator Air Bleed Screw
Change coolant according to engine
manual. Add coolant according to Section 4-3).
Run engine until engine reaches normal
operating temperature. Loosen air bleed
screw to remove air from cooling system.
Tighten screw.
Check coolant level in recovery tank. Add
coolant if necessary
1
3
2
802 579-A / 802 581
OM-4401 Page 31
7-7. Adjusting Engine Speed
After tuning engine, check engine
speeds with a tachometer (see
table). If necessary, adjust speeds
as follows:
2450 ± 100 rpm
3750 Max
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
Throttle Solenoid
Idle Speed Jam Nut
Idle Speed Screw
Loosen nut and turn screw clockwise to increase idle speed. Turn
screw counterclockwise to decrease idle speed. Tighten nut.
See engine manual for governor
sensitivity adjustment.
Adjusting Weld/Power Speed
4
5
Weld Speed Jam Nut
Adjustment Screw
Turn Engine Control switch to Run
position. Loosen nut and turn screw
counterclockwise to increase
speed. Turn screw clockwise to decrease speed. Tighten nut.
Using Engine Stop Lever
6
Engine Stop Lever
Use lever to stop engine if Engine
Control switch does not work.
4
5
3
1
2
6
Tools Needed:
10 mm
Ref. 802 579-A
OM-4401 Page 32
7-8. Overload Protection
Stop engine.
Tools Needed:
3/8 in
When a circuit breaker opens,
it usually indicates a more serious problem exists. Contact
Factory Authorized Service
Agent.
1 Circuit Breaker CB5
CB5 protects the 24 volt ac output
to Remote 14 receptacle RC1. If
CB5 opens, 24 volt ac output to
RC1 stops.
2 Circuit Breaker CB6
CB6 protects the 115 volt ac output
to Remote 14 receptacle RC5. If
CB6 opens, 115 volt ac output to
RC5 stops.
Press button to reset breaker.
3 Circuit Breaker CB7
4 Circuit Breaker CB8
5 Circuit Breaker CB9
6 Circuit Breaker CB10
1
CB7 protects the engine glow plug
from overload. If CB7 opens, the
glow plug does not work and engine
may not start in cold weather.
Check continuity and connections
of engine glow plug.
2
CB8 protects the engine wiring system from overload. If CB8 opens,
the engine will not crank. Check
battery, starter, and engine control
switch.
CB9 protects the engine throttle circuit from overload. If CB9 opens,
the engine will not run at idle speed.
Check throttle solenoid TS1 for obstructions.
6
5
4
3
8
7
CB10 protects the engine fuel solenoid from overload. If CB10 opens,
the engine cranks but does not
start. Check fuel solenoid FS1 for
obstructions.
7
8
Fuse F1 (See Parts List)
Fuse F2 (See Parts List)
Remove side panel.
F1 protects the exciter excitation
winding from overload. If F1 opens,
auxiliary power output stops or is
low. Weld output is still available.
F2 protects the stator winding from
overload. If F2 opens, weld output
stops. Auxiliary power is still available.
Replace any open fuses. Reinstall
cover before operating unit.
802 580-A / 802 581
OM-4401 Page 33
7-9. Troubleshooting
A. Welding
Trouble
Remedy
No weld output; auxiliary power output Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and
okay.
connect remote contactor to optional Remote 14 receptacle RC1 (see Section 4-8).
Check position of polarity switch.
Reset circuit breaker(s) CB5 and CB6 (see Section 7-8). Check for faulty remote device connected to
RC1.
Check and secure connections to Remote 14 receptacle RC14 (see Section C).
Have Factory Authorized Service Agent check capacitor board PC4 and connections.
Check fuse F2, and replace if open (see Section 7-8).
Have Factory Authorized Service Agent check brushes and slip rings, field excitation circuit, field current
control board PC2, and the rotor.
No weld output or auxiliary power output. Disconnect equipment from auxiliary power receptacles during start-up.
Check fuses F1 and F2, and replace if open (see Section 7-8).
Have Factory Authorized Service Agent check brushes and slip rings, integrated rectifier SR2, field excitation circuit, field current control board PC2, and the rotor.
Erratic weld output.
Check control settings.
Clean and tighten connections both inside and outside unit.
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 7-7).
Check and secure lead connections to remote A/V control.
Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2.
High weld output.
Check position of Voltage/Amperage Adjust control.
Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent check field current regulator board PC2.
Low weld output.
Check engine speed, and adjust if necessary.
Check fuse F2, and replace if open (see Section 7-8).
Have Factory Authorized Service Agent check brushes and slip rings, integrated rectifier SR2, field excitation circuit, field current control board PC2, and the rotor.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
Weld output cannot be adjusted.
Check position of Voltage/Amperage Adjust switch (see Section 5-1).
No power output at Remote 14 receptacle RC1.
Reset circuit breaker CB5 and/or CB6 (see Section 6-1).
No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position.
control.
Check and secure connections to Remote 14 receptacle RC1 (see Section 4-8).
Repair or replace remote control device.
OM-4401 Page 34
Trouble
Min or max CV weld output only.
Remedy
Check position of Voltage/Amperage Adjustment control and Voltage/Amperage Adjust switch (see Section 5-1).
Repair or replace remote control device.
Have Factory Authorized Service Agent check field current regulator board PC2.
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Welding arc.
Use proper size tungsten for welding amperage.
Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Wandering arc – poor control of arc
direction.
Reduce gas flow rate.
Select proper size tungsten. Properly prepare tungsten.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
B. Auxiliary Power
Trouble
No auxiliary power output; weld output
okay.
Remedy
Reset circuit breakers CB1, CB3 and/or CB4 (see Section 6-1).
Check fuse F1, and replace if necessary (see Section 7-8).
Have Factory Authorized Service Agent check brushes, slip rings, and voltage regulator board PC6.
No auxiliary power or weld output.
Disconnect equipment from auxiliary power receptacles during start-up.
Check fuses F1 and F2, and replace if necessary (see Section 7-8).
Have Factory Authorized Service Agent check brushes and slip rings, integrated rectifier SR2, field excitation circuit, field current control board PC2, and the rotor.
Low power output.
Check and clean air cleaner as necessary (see Section 7-4).
Check and adjust engine speed (see Section 7-7).
Have Factory Authorized Service Agent check voltage regulator board PC6.
See engine manual.
High power output.
Check and adjust engine speed (see Section 7-7).
Have Factory Authorized Service Agent check voltage regulator board PC6.
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.
OM-4401 Page 35
C. Engine
Trouble
Engine will not crank.
Remedy
Reset circuit breaker CB8 (see Section 7-8).
Check battery voltage.
Check battery connections and tighten if necessary.
Have Factory Authorized Service Agent check Engine Control switch S1.
Engine cranks, but does not start.
Check fuel level (see Section 4-2).
Open fuel valve (see Section 4-2).
Check oil level (see Section 4-2). Engine will not start if oil pressure is low.
Reset circuit breaker CB10 (see Section 7-8).
Check coolant level and fan belt (see Section 4-2 and engine manual). Engine will not start if coolant
temperature is high.
Use Glow Plug if unit does not start in cold weather. If unit still does not start, reset circuit breaker
CB7 (see Section 7-8).
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.
Have Factory Authorized Service Agent check low oil pressure switch S4, engine coolant temperature switch S5, and control relay CR1.
See engine manual.
Engine starts but stops when Engine
Control switch is released.
Check oil level (see Section 4-2). Engine will not start if oil pressure is too low.
Reset circuit breaker CB10 (see Section 7-8).
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 engine manual).
Have Factory Authorized Service Agent check low oil pressure switch S4 and engine coolant temperature switch S5.
Engine does not stop.
Stop engine by pushing down engine stop lever (see Section 4-2) or closing fuel valve (see Section
4-2). After stopping engine, adjust fuel solenoid linkage (see engine manual).
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 switch S4 and engine coolant temperature switch S5.
Battery discharges between uses.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator according to engine manual.
OM-4401 Page 36
Trouble
Engine does not go to low (idle) speed
with Engine Speed switch in Run/Idle
position.
Remedy
Be sure Engine Speed switch is in Run/Idle position.
Remove all weld and auxiliary power loads.
Turn off remote device connected to Remote 14 receptacle RC1 (see Section 4-8).
Check for obstructed movement of throttle solenoid linkage.
Have Factory Authorized Service Agent check timer module and current transformer CT1.
Reset circuit breaker CB9 (see Section 7-8).
Engine does not go to high (run) speed
when auxiliary power or large weld
load is applied with Engine Speed
switch in Run/Idle position.
Place Engine Speed switch in the Run position. Have Factory Authorized Service Agent check unit.
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine (see Section 9 and engine manual).
Coolant recovery tank continuously
overflows.
Bleed air from radiator, and replace lost coolant (see Section 4-3).
Notes
OM-4401 Page 37
SECTION 8 – ELECTRICAL DIAGRAMS
Figure 8-1. Circuit Diagram For Welding Generator
OM-4401 Page 38
198 518-A
OM-4401 Page 39
SECTION 9 – RUN-IN PROCEDURE
run_in4 6/99
9-1. Wetstacking
1
Welding Generator
Run diesel engines near rated output during run-in period to properly
seat piston rings and prevent wetstacking. See nameplate or rating
label to find rated output.
2
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.
1
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-4401 Page 40
9-2. 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.
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
4
2
Welding Generator
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe
correct
polarity.
1
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator V/A control so load
equals 225 amps at 30 volts.
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
Check oil level frequently during run-in; add oil if needed.
After one hour (minimum) place V/A
control in minimum position, then
turn off load bank to remove load.
Run engine several minutes at no
load.
3
Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0683
OM-4401 Page 41
9-3. 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.
1 Resistance Grid
Use grid sized for generator rated
output.
Turn Off grid.
2
6
1
2
Welding Generator
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connectors (polarity is not important).
4
Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several
minutes.
Set grid switches and then adjust
generator V/A control so load
equals 225 amps at 30 volts.
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
3
5
Check oil level frequently during run-in; add oil if needed.
4
+
After one hour (minimum), place
V/A control in minimum position,
then shut down grid to remove load.
Run engine several minutes at no
load.
Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
OM-4401 Page 42
SECTION 10 – AUXILIARY POWER GUIDELINES
10-1.
Selecting Equipment
1
2
3
Auxiliary 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 2/99 – Ref. ST-159 730 / ST-800 577
10-2.
Grounding Generator To Truck Or Trailer Frame
1
2
3
4
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
3
1
4
GND/PE
OR
2
2
Electrically bond generator
frame to vehicle frame by
metal-to-metal contact.
S-0854
OM-4401 Page 43
10-3.
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
10-4.
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 10-8).
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-4401 Page 44
10-5.
Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
10-6.
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
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-4401 Page 45
10-7.
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-4401 Page 46
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
10-8.
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
10-9.
S-0624
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-4401 Page 47
10-10. Typical Connections To Supply Standby Power
1
2
3
Obtain and install correct switch.
Switch rating must be same as or
greater than the branch overcurrent
protection.
Customer-supplied equipment is required if
generator is to supply standby power during
emergencies or power outages.
4
1
5
120 V
6
Generator Connections
Connect terminals or plug of adequate amperage capacity to cord.
Follow all applicable codes and
safety practices.
Neutral
2
Extension Cord
Select as shown in Section 10-11.
120 V
3
240 V
120 V
Load
Circuit Breakers or Fused
Disconnect Switch
Obtain and install correct switch.
240 V
120/240 Volt
60 Hz
Three-Wire
Service
Power Company Service
Meter
Main and Branch Overcurrent
Protection
Double-Pole, Double-Throw
Transfer Switch
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
120 V
Load Connections
4
7
CB
or
Item 4 is not necessary if circuit
protection is already present in
welding generator auxiliary
power output circuit.
F1
6
5
240 V
120/240 Volt
Single-Phase
Three-Wire
Generator Output
Connection
120 V
120 V
Ground
S-0405-A
OM-4401 Page 48
10-11. 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-4401 Page 49
SECTION 11 – PARTS LIST
Hardware is common and
not available unless listed.
18
19
17
16
15
7
14
12 13
11
20
6
10
8
4
9
3
21
22
102
103
29
2
23 – FIG 11-2
30
31
32 33
28
34
35
1
36
104
27
26
25
24
101 –FIG 11-3
24
97
98
100
99
Figure 11-1. Main Assembly
OM-4401 Page 50
64
105
63
62
65
61
60
17
66
59
17
58
57
56
67
68
40
41
69
54
39
71
38
72
53
37–FIG 11–4
70
55
73
74
76
75
42
52
48
47
94
43
44
45
46
77
51
49
78
92
50
106
93
91
79
81
80
90
82
89
84
86
83
85
88
87
96
95
802 625-A
OM-4401 Page 51
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . 1 . . . . . . . . . . . . . . 013367
. . 2 . . . . . . . . . . . . +198157
. . 3 . . . . . . . . . . . . . . 134792
. . 4 . . . . . . . . . . . . +198155
. . 5 . . . . . . . . . . . . . Deleted
. . 6 . . . . . . . . . . . . . . 192041
. . 7 . . . . . . . . . . . . . . 198159
. . 8 . . . . . . . . . . . . . . 108487
. . 9 . . . . . . . . . . . . . . 193411
. . 10 . . . . . . . . . . . +198156
. . 11 . . . . . . . . . . . . . 198525
. . 12 . . . . . . . . . . . +198164
. . 13 . . . . . . . . . . . . . 194320
. . 14 . . . . . . . . . . . . . 194295
. . 15 . . . . . . . . . . . +198162
. . 16 . . . . . . . . . . . . . 191623
. . 17 . . . . . . . . . . . . . 109591
. . 18 . . . . . . . . . . . . 201 882
. . 19 . . . . . . . . . . . . . 198153
. . 20 . . . . . . . . . . . . . 176230
. . 21 . . . . . . . . . . . . . 194320
. . 22 . . . . . . . . . . . +198154
. . 23 . . . . . . . . . Figure 11-2
. . 24 . . . . . . . . . . . . . 198167
. . . . . . . . . . . . . . . . . . . 198539
. . 25 . CB9,10 . . . . 139266
. . 26 . . CB8 . . . . . 115427
. . 27 . . CB7 . . . . . 147658
. . . . . . . . . C3 . . . . . 199 451
. . . . . . . . RC25 . . . . . 166679
. . . . . . . PLG27 . . . . 192170
. . . . . . . PLG36 . . . . 192169
. . . . . . . PLG28 . . . . 192171
. . . . . . . PLG37 . . . . 192168
. . . . . . . PLG11 . . . . 130204
. . . . . . . . . . . . . . . . . . . 192167
. . . . . . . . . . . . . . . . . . . 187654
. . 28 . . . . . . . . . . . . . 198054
. . . . . . . . . . . . . . . . . . . 199019
. . 29 . . CR2 . . . . . 155309
. . 30 . . . . . . . . . . . . . 010381
. . 31 . . . . . . . . . . . . . 193414
. . 32 . . . . . . . . . . . . . 172296
. . 33 . . . . . . . . . . . . . 192239
. . 34 . . . . . . . . . . . . . 190323
. . 35 TIMER MODULE . . 198882
. . 36 . . . . . . . . . . . . . 197265
. . 37 . . . . . . . . . Figure 11-4
. . 38 . . . S4 . . . . . *197145
. . 39 . . . . . . . . . . . . . 193624
. . 40 . . . . . . . . . . . . . 192517
. . 41 . . . S5 . . . . . *192190
. . 42 . . . . . . . . . . . . . 192475
. . 43 . . . . . . . . . . . . . 118829
. . 44 . . . . . . . . . . . . . 194127
. . 45 . . . . . . . . . . . . . 145675
. . 46 . . TS1 . . . . . 192196
. . 47 . . . . . . . . . . . . . 192663
. . 48 . . . . . . . . . . . . . 047235
. . 49 . . . . . . . . . . . . . 047361
OM-4401 Page 52
. . Label, Warning Moving Parts Can Cause Serious Etc . . . . . . . . . . . . . . . . . 1
. . Panel, Generator Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning General Precautionary Engine Drive . . . . . . . . . . . . . . . . . . 1
. . Cover, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.....................................................................
. . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Tray, fuel spill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning:Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . . 1
. . Brace, Hood Access Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hinge, Door Access 180 Deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Hood, Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Latch, Lever Flush Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Label, Diesel Engine Maintenance Kubota 905/1005 . . . . . . . . . . . . . . . . . . 1
. . Plenum, Radiator Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning All Panels Must Be In Place While Ru . . . . . . . . . . . . . . . . . 1
. . Clamp, Muffler 1.750 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Pipe, Exhaust Elbow 1.654 ID Stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Latch, Lever Flush Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Door, Access Removable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Mounting bracket w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Support, Weld Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Harness, Wrg Engine Compartment (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . . 2
. . . . Circuit Breaker, Man Reset 1p 25a 250vac Frict . . . . . . . . . . . . . . . . . . . . 1
. . . . Circuit Breaker, Man Reset 1p 30a 250vac Screw . . . . . . . . . . . . . . . . . . . 1
. . . . Alternator Filter/Capacitor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg (service kit) . . . 1
. . . . Conn, Rect 250 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect 250 1skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect 250 3skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect 250 1pin 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg (service kit) . . . . . . . . . . 1
. . . . Seal,Wire Univ 3p/S 1row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Upright, Base Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Seal, Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Contactor, Solenoid 12vdc Continuous 400a Inrush . . . . . . . . . . . . . . . . . . . 1
. . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Gas Spring Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ball Gas Spring, Stud .39 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Spring, Pressure Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Module, Solenoid Control W/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Switch, Pressure Oil 7psi No Screw Term . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Engine, Kubota Dsl Elec Dh905b–1 (Consisting Of) . . . . . . . . . . . . . . . . . . . 1
. . . . Gasket, Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Switch, Thermo Temp 230deg +/–5deg F No . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Support, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Screw, Shld Stl Sch .312–18 X .500 X .375 Shld . . . . . . . . . . . . . . . . . . . . 1
. . . . Linkage, Throttle Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Nut, 312–18 .50hex .37h Stl Pld Deformed Lkg Thrd . . . . . . . . . . . . . . . . . 1
. . . . Solenoid, 12vdc 46a Push/Hold W/Amp Connect & Seal . . . . . . . . . . . . . 1
. . . . Bracket, Mtg Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Washer, Seal Oil Copper .879id X 1.059od 111–8737 . . . . . . . . . . . . . . . . 2
. . . . Ftg, Banjo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (Continued)
. . 50 . . . . . . . . . . . . . 047234 . . . . Banjo Bolt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 51 . . . . . . . . . . . . . 192511 . . . . Hose, Oil W/Fittings 20.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 52 . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8–18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adapter, Engine (see Figure 11-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 53 . . . . . . . . . . . +187462 . . . . Bottle, overflow w/cap & hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 54 . . . . . . . . . . . . . 192934 . . . . Bracket, mtg coolant recovery tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 55 . . . . . . . . . . . . . 197671 . . Label, Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 56 . . . . . . . . . . . . . 192194 . . Pipe, Exhaust Flexible Inlet W/Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 57 . . . . . . . . . . . . . 197146 . . Fan, Engine 330mm Pusher Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . *197197 . . Belt, Fan Kubota 905 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 58 . . . . . . . . . . . +191693 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 59 . . . . . . . . . . . . . 198936 . . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 60 . . . . . . . . . . . . . 191341 . . Hose, Radiator Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 61 . . . . . . . . . . . . . 198186 . . Bracket, Mtg Radiator Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 62 . . . . . . . . . . . . . 197822 . . Radiator, w/14# Cap 3 Row Core 1.125 Inlet/Outlet . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 187120 . . Cap, radiator pressure 14 lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 63 . . . . . . . . . . . . . 194578 . . Baffle, Foam Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 64 . . . . . . . . . . . . . 198181 . . Radiator Arch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 65 . . . . . . . . . . . . . 192195 . . Pipe, Exhaust Outlet 1.625 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 66 . . . . . . . . . . . . . 147923 . . Label, Warning Moving Parts Can Cause Serious Injur . . . . . . . . . . . . . . . .
. . 67 . . . . . . . . . . . . 201 528 . . Muffler, Exhaust Engine Kubota Dh905b–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 68 . . . . . . . . . . . . . 198187 . . Bracket, Mtg Radiator Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 69 . . . . . . . . . . . . . 198185 . . Baffle, Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 70 . . . . . . . . . . . . . 191342 . . Hose, Radiator Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 71 . . . . . . . . . . . . . 191515 . . Base, Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 72 . . . . . . . . . . . . *192744 . . Filter, Fuel Spin–on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 73 . . . . . . . . . . . . *066113 . . Filter, Fuel Inline .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 74 . . . . . . . . . . . . *196428 . . Filter, Oil Kubota 905dh/1005dh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 75 . . . . . . . . . . . . . 192476 . . Mount, Engine Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 76 . . . . . . . . . . . . . 192188 . . Air Cleaner, Intake 90deg Outlet 4.25in Dia. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . *187441 . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . ♦202102 . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 77 . . . . . . . . . . . . . 193026 . . Band, Mtg Air Cleaner Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 78 . . . . . . . . . . . . . 197256 . . Hose, Elbow Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 79 . . . . . . . . . . . . . 197227 . . Hose, Elbow Air Cleaner 1.750id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 80 . . . . . . . . . . . . . 032453 . . Cable, Bat Neg 24.375 No 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . .
. . 81 . . . . . . . . . . . . . 182935 . . Hold Down, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 82 . . BATT . . . . . 146237 . . Battery, Stor 12v 535 Crk 90 Rsv Gp 55 Maint Free . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 108081 . . Terminal Protector, Battery Post Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 83 . . . . . . . . . . . . . 114923 . . Boot, Insulator Term Post Red 1/0 Cable .875odx1.00 . . . . . . . . . . . . . . . . .
. . 84 . . . . . . . . . . . . . 182276 . . Cable, Bat Pos 28.000 No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . . . .
. . 85 . . . . . . . . . . . . . 097829 . . Bolt, J Stl .250–20 X 2.750 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 86 . . . . . . . . . . . . 147 988 . . Strip, Rbr Adh Back .125 X 1.000 X 4.000 60 Duro . . . . . . . . . . . . . . . . . . .
. . 87 . . . . . . . . . . . . 200 407 . . Strap, Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 88 . . . . . . . . . . . . . 198168 . . Support, Fuel Tank/Weld Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 89 . . . . . . . . . . . . . 198180 . . Tank, Fuel 13.1 Gal (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 90 . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 91 . . . . . . . . . . . . . 198510 . . . . Ftg, Stand Pipe Hose .3125 X24.570lg 90 Deg Zinc . . . . . . . . . . . . . . . . .
. . 92 . . . . . . . . . . . . . 198511 . . . . Ftg, Stand Pipe Hose .1875x24.570lg 90 Deg Zinc . . . . . . . . . . . . . . . . . .
. . 93 . . . . . . . . . . . . . 190198 . . . . Cap, Tank Screw–on 3.500 In W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 94 . . . . . . . . . . . . . 198512 . . . . Sender, Fuel Gauge 22.500 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 95 . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 96 . . . . . . . . . . . . . 181572 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 97 . . . . . . . . . . . +197835 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 98 . . . . . . . . . . . . . 197930 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 99 . . . . . . . . . . . . . 192477 . . Mount, Generator Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 100 . . . . . . . . . . . . . 199701 . . Panel, Front Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 101 . . . . . . . . . Figure 11-3 . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
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1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
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1
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1
2
2
1
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1
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1
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1
OM-4401 Page 53
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (Continued)
. 102 . . . . . . . . . . . . . 090281 . . Label, Caution Do Not Use Ether – Use Glow Plugs Et . . . . . . . . . . . . . . . . 1
. 103 . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 104 . . . . . . . . . . . +198158 . . Panel, Generator Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 105 . . . . . . . . . . . . 191 626 . . Bumper, door access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 106 . . . . . . . . . . . . 110 465 . . Tubing, corrugated plastic slit .500 dia xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ft
. . . . . . . . . . . . . . . . . . . 194126 . . Kit, Acoustical Foam Noise Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 168864 . . Seal, Rubber D .375 High X .750 Wide (door/panel seal) . . . . . . . . . . . . . 2.896 ft
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
14
Hardware is common and
15
not available unless listed.
13
12
10
8
9
11
7
6
16
17
5
4
18
3
19
20
2
1
28
27
26
25
24
23
21
22
802 642
Figure 11-2. Mounting Bracket w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Mounting Bracket w/Components (Figure 11-1, Item 23)
. . 1 . . . . . . . . . . . . . . 198171 . . Frame, Mtg Stab/Rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . 198174 . . Bracket, Mtg Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . SR1 . . . . . 198514 . . Rectifier, Si 3ph 350 Amp 400 Piv 100% Duty Cycle . . . . . . . . . . . . . . . . . . 1
OM-4401 Page 54
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Mounting Bracket w/Components (Continued)
. . 4 . . . SR2 . . . . . 035704
. . 5 . . C1, C2 . . . . 087110
. . 6 . . . . . . . . . . . . . . 177136
. . 7 . . . . D6 . . . . . . 135184
. . 8 . . . . . . . . . . . . . . 176199
. . 9 . . . PC2 . . . . 202 013
. . 10 . . . . . . . . . . . . . 176007
. . 11 . . . T1 . . . . . . 035759
. . 12 . . . . . . . . . . . . . 070026
. . 13 . . . . . . . . . . . . . 198177
. . 14 . . . . . . . . . . . . . 199037
. . 15 . . DC-Z . . . . . 198944
. . 16 . . . . . . . . . . . . . 192303
. . 17 . . PC6 . . . . . 199517
. . 18 . . . . . . . . . . . . . 176478
. . 19 . . . . . . . . . . . . . 198178
. . 20 . R4, R5 . . . . 139812
. . 21 . . . . . . . . . . . . . 198179
. . . . . . . . . . . . . . . . . . . 198538
. . 22 . . CR1 . . . . . 173069
. . 23 . . . . . . . . . . . . . 172731
. . . . . . . F1, F2 . . . *169296
. . 24 . . . 2T . . . . . . 197147
. . 25 . . . D3 . . . . . . 135184
. . 26 . D4, D5 . . . . 189701
. . . . . . . PLG12 . . . . 148850
. . . . . . . . . . . . . . . . . . . 200104
. . . . . . . . RC25 . . . . . 158465
. . . . . . . PLG35 . . . . 177859
. . . PLG33, PLG34 . 153501
. . . . . . . PLG23 . . . . 113634
. . . . . . . . . . . . . . . . . . . 187654
. . 27 . . . 1T . . . . . . 172661
. . 28 . . . . . . . . . . . . . 173734
. . . . . . . . PLG6 . . . . . 136924
. . . . . . . PLG22 . . . . 135134
. . . . . RC7, PLG10 . . 136925
. . . . . . . . . . . . . . . . . . . 198536
. . . . . . . . PLG9 . . . . . 135134
. . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Diode Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Capacitor 1.375 Dia Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Field Current Controller (consisting of) . . . . . . . . . . . . . .
. . . . Capacitor, Elctlt 1200 Uf 300 Vdc Can 1.37 Dia . . . . . . . . . . . . . . . . . . . . .
. . Xfmr, Control Mintr 115/36 Vct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stand–off, No 6–32 X .437 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Support Control Board Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stabilizer, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Stand–off Support, Pc Card No 6 Screw W/Post&lock M . . . . . . . . . . . . .
. . Tray, Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Resistor, Ww Fxd 30 W 5k Ohm Faston Te . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Harness, Wrg Interconnecting (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg . . . . . . . . . . . . . . . . . . .
. . . . Holder, Fuse Mintr .250 X 1.250 Clip Anti–pivot . . . . . . . . . . . . . . . . . . . . .
. . . . Fuse, Mintr Gl 25. Amp 125 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Block, Term 5–4–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Diode Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Diode/capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Push 6 Wire 12–16strnd 12–18sld 16–22tinstrnd . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . .
. . . . Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg (service kit) . . . . . . . . . .
. . . . Conn, Rect Univ 084 6p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . .
. . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Conn, Rect Comm 093 2p/S 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . Conn, Rect Univ 084 9p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . .
. . Conn, Rect Comm 093 2p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . Harness, Wrg Feedback (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Conn, Rect Univ 084 9p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . .
1
2
2
1
2
1
1
1
6
1
1
1
2
1
4
1
2
1
1
1
2
2
1
1
2
1
1
1
1
2
1
1
1
2
1
1
2
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4401 Page 55
Hardware is common and
13
not available unless listed.
4
5
3
7
6
8
9
10
11
2
1
14
15
16
44
17
12
21
43
18
28
42
38
41
39
22
40
23
24
37
25
36
35
30
31
29
45
28
19
6
26
34
33
32
27
802 642-A
Figure 11-3. Front Panel
OM-4401 Page 56
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Front Panel (Figure 11-1, Item 101)
. . 1 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . 200 928 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . S1 . . . . . . 187190 . . Switch, Changeover (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 187189 . . . . Bracket, Shunt Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . Shunt . . . . . 030080 . . Shunt, Meter 50mv 400 Amp Lt Wt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187121 . . Cable, Current Feedback 17 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . 134 201 . . Stand–off Support, PC Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . . . 6
. . 7 . . . PC5 . . . . . 148030 . . Circuit Card Assy, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . CT2 . . . ♦200284 . . Xfmr, Current 310/5 W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . S6 . . . . . . 200350 . . Switch, 6 Position W/Leads & Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 198534 . . Harness, Wrg Control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . 035897 . . . . Pot, Cp Std Slot 1t 2. W 1k Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . S3 . . . . . . 011611 . . . . Switch,Tgl Dpdt 15a 125vac On–none–on Spd Term Chr . . . . . . . . . . . . . 1
. . 12 CB5, CB6 . . . 083432 . . . . Circuit Breaker,Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG8 . . . . . 135275 . . . . Conn,Rect Univ 084 15p/S 3row Plug Cable Lkg (service kit) . . . . . . . . . 1
. . . . . . . . PLG2 . . . . . 165668 . . . . Conn,Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC24 . . . . . 135133 . . . . Conn,Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187655 . . . . Seal,Wire Univ 15p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . 198049 . . Upright, Base Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . PC4 . . . . . 147554 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . S2 . . . . . . 198515 . . Switch, Ignition 4 Position (2 Moment)W/Out Handle . . . . . . . . . . . . . . . . . . 1
. . 16 . . PC1 . . . . . 202124 . . Module, Pull To Idle 4 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . S7 . . . . . . 200351 . . Switch, 3 Position W/Leads & Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 GFCI-4,5 . . . . 151981 . . Rcpt,Str Dx Grd 2p3w 15/20a 125v *5–20r Gfi . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . PC3 . . . . . 148021 . . Circuit Card Assy, Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 21 CB3,CB4 . . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . . 2
. . 22 . . CB1 . . . . 200 929 . . Circuit Breaker, Man Reset 2p 50a 240vac Screw–90 . . . . . . . . . . . . . . . . . . 1
. . 23 . . . . . . . . . . . . . 083030 . . Stud, Brs .250–20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . . . . . . . . . 601836 . . Nut, 250–20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 25 . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 26 . . . . . . . . . . . . . 099255 . . Terminal, Pwr Output Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 27 . . . . . . . . . . . . . 188039 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . . . 2
. . 29 . . . . . . . . . . . . . 119014 . . Lever, Switch Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 30 . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 31 . . RC3 . . . . . 182954 . . Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14–50 . . . . . . . . . . . . . . . . . . . . . . 2
. . 32 . . PL1 . . . . . . 191935 . . Led, Red 12.0v 4 Ind Lights Spl Panel Mtg Round . . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . HM . . . . . . 118058 . . Meter, Hour 12–24vdc 2.25 Dia High Profile Stainles . . . . . . . . . . . . . . . . . . 1
. . 34 . . . FG . . . . . . 192265 . . Gauge, Fuel Elec Switch W/O Switchgage Sensor . . . . . . . . . . . . . . . . . . . . 1
. . 35 . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 36 . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 37 . . . . . . . . . . . . . 097924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . 1
. . 38 . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 39 . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 40 . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 41 . . . A . . . . . ♦200230 . . Meter, Amp Ac/Dc 0– 310 0–420 Dc Scale 2.5 In . . . . . . . . . . . . . . . . . . . . . . 1
. . 42 . . . V . . . . . ♦164874 . . Meter, Volt Ac/Dc 0– 100 Scale 2.5 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 43 . . . . . . . . . . . . . 115493 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 44 . . CT1 . . . . . 198623 . . Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 048489 . . Clamp, Nyl 1.000 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . . . 1
. . 45 . . . . . . . . . . . . . 200930 . . Boot, circuit breaker 1 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4401 Page 57
. Hardware is common and
9
not available unless listed.
8
7
6
5
3
4
1
10
2
11
12
17 16
15
14
13
802 641
Figure 11-4. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-4. Generator Assembly (Figure 11-1, Item 37)
. . 1 . . . . . . . . . . . . . . 187536
. . 2 . . . . . . . . . . . . . . 183419
. . 3 . . . . . . . . . . . . . 203 686
. . 4 . . . . . . . . . . . . . . 181143
. . 5 . . . . . . . . . . . . . . 192600
. . 6 . . . . . . . . . . . . +198930
. . 7 . . . . . . . . . . . . . . 013367
. . 8 . . . . . . . . . . . . . . 159918
. . 9 . . . . . . . . . . . . . . 193515
. . 10 . . . . . . . . . . . . . 187151
. . 11 . . . . . . . . . . . . . 010910
. . 12 . . . . . . . . . . . . . 010909
. . 13 . . . . . . . . . . . . . 047878
. . 14 . . . . . . . . . . . . . 161306
. . 15 . . . . . . . . . . . . *126984
. . 16 . . . . . . . . . . . . . 005614
. . 17 . . . . . . . . . . . . . 187183
. . . . . . . . RC6 . . . . . 136924
. . . . . . . . RC10 . . . . . 136925
. . Endbell (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O–ring, 1.984 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Rotor, Generator (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . . .
. . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stator, Generator (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label,Warning Moving Parts Can Cause Serious Etc. . . . . . . . . . . . . . . . . . .
. . Baffle, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Adapter, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stud, Stl .375–16 X 21.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Flat .406idx0.812odx.065t Stl Pld Ansi.375 . . . . . . . . . . . . . . . . . . .
. . Nut, 375–16 .56hex .46h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . .
. . Bar, Retaining Brushholder 3 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cap, Brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Brush W/Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Holder, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Brushholder 3 Brush Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Conn, Rect Comm 093 2p/S 1row Rcpt Cable Lkg . . . . . . . . . . . . . . . . . . . .
. . Conn, Rect Comm 093 2p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
4
4
4
1
3
3
3
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4401 Page 58
Effective January 1, 2000
(Equipment with a serial number preface of “LA” 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
185 & Spoolmate 250)
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 185 & Spoolmate 250
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 7/00
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
 2001 Miller Electric Mfg. Co.
1/01
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