Big Blue 300 D PRO 300 D: OM-236 949A Processes

Download as pdf or txt
Download as pdf or txt
You are on page 1of 74

OM-236 949A

2008−02
Processes
Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A)


Cutting and Gouging

Description

Engine Driven Welding Generator

Big Blue 300 D


®

PRO 300 D

File: Engine Drive

Visit our website at


www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard. particular model are also provided.

Miller Electric manufactures a full line


of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 2005−04
TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 9
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-6. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-4. Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-6. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-7. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-8. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-9. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-10. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-11. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-4. Lift-Arc TIG With Auto-Crater And Auto-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-6. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-1. Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TABLE OF CONTENTS

8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38


8-5. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-6. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-7. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-8. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-9. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-10. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
WARRANTY
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2007−04

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage


DANGER! − Indicates a hazardous situation which, if  Indicates special instructions.
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex- SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text. bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.

1-2. Arc Welding Hazards


 Always verify the supply ground — check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information  When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-7. Read and tor first − double-check connections.
follow all Safety Standards.  Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and  Frequently inspect input power cord for damage or bare wiring —
repair this unit. replace cord immediately if damaged — bare wiring can kill.
 Turn off all equipment when not in use.
During operation, keep everybody, especially children, away.  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
ELECTRIC SHOCK can kill. with a separate cable.
 Do not touch electrode if you are in contact with the work, ground,
Touching live electrical parts can cause fatal shocks or or another electrode from a different machine.
severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input  Use only well-maintained equipment. Repair or replace damaged
power circuit and machine internal circuits are also live when power is parts at once. Maintain unit according to manual.
on. In semiautomatic or automatic wire welding, the wire, wire reel,  Do not touch electrode holders connected to two welding ma-
drive roll housing, and all metal parts touching the welding wire are chines at the same time since double open-circuit voltage will be
electrically live. Incorrectly installed or improperly grounded equip- present.
ment is a hazard.  Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Do not touch live electrical parts.
 Clamp work cable with good metal-to-metal contact to workpiece
 Wear dry, hole-free insulating gloves and body protection. or worktable as near the weld as practical.
 Insulate yourself from work and ground using dry insulating mats  Insulate work clamp when not connected to workpiece to prevent
or covers big enough to prevent any physical contact with the work contact with any metal object.
or ground.  Do not connect more than one electrode or work cable to any
single weld output terminal.
 Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling. SIGNIFICANT DC VOLTAGE exists in inverters after stop-
 Use AC output ONLY if required for the welding process. ping engine.
 Stop engine on inverter and discharge input capacitors according
 If AC output is required, use remote output control if present on to instructions in Maintenance Section before touching any parts.
unit.
 Additional safety precautions are required when any of the follow- HOT PARTS can cause severe burns.
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such  Do not touch hot parts bare handed.
as floors, gratings, or scaffolds; when in cramped positions such  Allow cooling period before working on equip-
as sitting, kneeling, or lying; or when there is a high risk of unavoid- ment.
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a  To handle hot parts, use proper tools and/or wear heavy, insu-
semiautomatic DC constant voltage (wire) welder, 2) a DC manual lated welding gloves and clothing to prevent burns.
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder FLYING METAL or DIRT can injure eyes.
is recommended. And, do not work alone!
 Disconnect input power or stop engine before installing or  Welding, chipping, wire brushing, and grinding
servicing this equipment. Lockout/tagout input power according to cause sparks and flying metal. As welds cool,
OSHA 29 CFR 1910.147 (see Safety Standards). they can throw off slag.
 Properly install and ground this equipment according to its  Wear approved safety glasses with side shields even under your
Owner’s Manual and national, state, and local codes. welding helmet.

OM-236 949 Page 1


 Do not weld on closed containers such as tanks, drums, or pipes,
FUMES AND GASES can be hazardous. unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Welding produces fumes and gases. Breathing these  Do not weld where the atmosphere may contain flammable dust,
fumes and gases can be hazardous to your health. gas, or liquid vapors (such as gasoline).
 Keep your head out of the fumes. Do not breathe the fumes.  Connect work cable to the work as close to the welding area as
 If inside, ventilate the area and/or use local forced ventilation at the practical to prevent welding current from traveling long, possibly
arc to remove welding fumes and gases. unknown paths and causing electric shock, sparks, and fire haz-
ards.
 If ventilation is poor, wear an approved air-supplied respirator.
 Read and understand the Material Safety Data Sheets (MSDSs)  Do not use welder to thaw frozen pipes.
and the manufacturer’s instructions for metals, consumables,  Remove stick electrode from holder or cut off welding wire at
coatings, cleaners, and degreasers. contact tip when not in use.
 Work in a confined space only if it is well ventilated, or while  Wear oil-free protective garments such as leather gloves, heavy
wearing an air-supplied respirator. Always have a trained watch- shirt, cuffless trousers, high shoes, and a cap.
person nearby. Welding fumes and gases can displace air and  Remove any combustibles, such as a butane lighter or matches,
lower the oxygen level causing injury or death. Be sure the breath- from your person before doing any welding.
ing air is safe.
 After completion of work, inspect area to ensure it is free of sparks,
 Do not weld in locations near degreasing, cleaning, or spraying op- glowing embers, and flames.
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.  Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
 Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld  Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
area, the area is well ventilated, and while wearing an air-supplied for hot work and have a fire watcher and extinguisher nearby.
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded. NOISE can damage hearing.

BUILDUP OF GAS can injure or kill. Noise from some processes or equipment can dam-
age hearing.
 Shut off shielding gas supply when not in use.
 Wear approved ear protection if noise level is
 Always ventilate confined spaces or use ap- high.
proved air-supplied respirator.
MAGNETIC FIELDS can affect Implanted
ARC RAYS can burn eyes and skin. Medical Devices.

 Wearers of Pacemakers and other Implanted


Arc rays from the welding process produce intense Medical Devices should keep away.
visible and invisible (ultraviolet and infrared) rays that
 Implanted Medical Device wearers should consult their doctor
can burn eyes and skin. Sparks fly off from the weld.
and the device manufacturer before going near arc welding, spot
 Wear an approved welding helmet fitted with a proper shade of filter welding, gouging, plasma arc cutting, or induction heating
lenses to protect your face and eyes from arc rays and sparks operations.
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards). CYLINDERS can explode if damaged.
 Wear approved safety glasses with side shields under your
helmet. Shielding gas cylinders contain gas under high pres-
 Use protective screens or barriers to protect others from flash, sure. If damaged, a cylinder can explode. Since gas
glare, and sparks; warn others not to watch the arc. cylinders are normally part of the welding process, be
 Wear protective clothing made from durable, flame-resistant mate- sure to treat them carefully.
rial (leather, heavy cotton, or wool) and foot protection.  Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
WELDING can cause fire or explosion.  Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Welding on closed containers, such as tanks, drums,  Keep cylinders away from any welding or other electrical circuits.
or pipes, can cause them to blow up. Sparks can fly off  Never drape a welding torch over a gas cylinder.
from the welding arc. The flying sparks, hot workpiece,  Never allow a welding electrode to touch any cylinder.
and hot equipment can cause fires and burns. Accidental contact of
electrode to metal objects can cause sparks, explosion, overheating,  Never weld on a pressurized cylinder — explosion will result.
or fire. Check and be sure the area is safe before doing any welding.  Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
 Remove all flammables within 35 ft (10.7 m) of the welding arc. If
associated parts in good condition.
this is not possible, tightly cover them with approved covers.
 Turn face away from valve outlet when opening cylinder valve.
 Do not weld where flying sparks can strike flammable material.
 Keep protective cap in place over valve except when cylinder is in
 Protect yourself and others from flying sparks and hot metal. use or connected for use.
 Be alert that welding sparks and hot materials from welding can  Use the right equipment, correct procedures, and sufficient num-
easily go through small cracks and openings to adjacent areas. ber of persons to lift and move cylinders.
 Watch for fire, and keep a fire extinguisher nearby.  Read and follow instructions on compressed gas cylinders,
 Be aware that welding on a ceiling, floor, bulkhead, or partition can associated equipment, and Compressed Gas Association (CGA)
cause fire on the hidden side. publication P-1 listed in Safety Standards.

OM-236 949 Page 2


1-3. Engine Hazards

BATTERY EXPLOSION can BLIND. STEAM AND HOT COOLANT can burn.

 Always wear a face shield, rubber gloves, and  If possible, check coolant level when engine is
protective clothing when working on a battery. cold to avoid scalding.
 Stop engine before disconnecting or connect-  Always check coolant level at overflow tank, if
ing battery cables or servicing battery. present on unit, instead of radiator (unless told
 Do not allow tools to cause sparks when working on a battery. otherwise in maintenance section or engine
manual).
 Do not use welder to charge batteries or jump start vehicles.
 If the engine is warm, checking is needed, and there is no over-
 Observe correct polarity (+ and −) on batteries. flow tank, follow the next two statements.
 Disconnect negative (−) cable first and connect it last.  Wear safety glasses and gloves and put a rag over radiator cap.
 Turn cap slightly and let pressure escape slowly before
FUEL can cause fire or explosion. completely removing cap.

 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. Using a generator indoors CAN KILL
 Do not overfill tank — allow room for fuel to expand. YOU IN MINUTES.
 Do not spill fuel. If fuel is spilled, clean up before starting engine.
 Generator exhaust contains carbon monoxide.
 Dispose of rags in a fireproof container.
This is a poison you cannot see or smell.
 Always keep nozzle in contact with tank when fueling.
 NEVER use inside a home or garage, EVEN IF
doors and windows are open.
 Only use OUTSIDE and far away from windows, doors, and
MOVING PARTS can cause injury. vents.
 Keep away from fans, belts, and rotors.
 Keep all doors, panels, covers, and guards
closed and securely in place.
BATTERY ACID can BURN SKIN and EYES.
 Stop engine before installing or connecting unit.
 Have only qualified people remove doors, panels, covers, or  Do not tip battery.
guards for maintenance and troubleshooting as necessary.  Replace damaged battery.
 To prevent accidental starting during servicing, disconnect  Flush eyes and skin immediately with water.
negative (−) battery cable from battery.
 Keep hands, hair, loose clothing, and tools away from moving
parts.
 Reinstall doors, panels, covers, or guards when servicing is ENGINE HEAT can cause fire.
finished and before starting engine.
 Before working on generator, remove spark plugs or injectors to  Do not locate unit on, over, or near combustible
keep engine from kicking back or starting. surfaces or flammables.
 Keep exhaust and exhaust pipes way from
 Block flywheel so that it will not turn while working on generator
flammables.
components.

HOT PARTS can cause severe burns.


 Do not touch hot parts bare handed. EXHAUST SPARKS can cause fire.
 Allow cooling period before working on equip-
ment.  Do not let engine exhaust sparks cause fire.
 To handle hot parts, use proper tools and/or  Use approved engine exhaust spark arrestor in
wear heavy, insulated welding gloves and required areas — see applicable codes.
clothing to prevent burns.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can TRAPPED AIR PRESSURE AND WHIPPING


cause serious injury or death. HOSES can cause injury.

 Do not use compressed air for breathing.  Release air pressure from tools and system be-
 Use only for cutting, gouging, and tools. fore servicing, adding or changing attach-
ments, or opening compressor oil drain or oil fill
cap.
COMPRESSED AIR can cause injury.
 Wear approved safety goggles.
 Do not direct air stream toward self or others.

OM-236 949 Page 3


HOT METAL from air arc cutting and READ INSTRUCTIONS.
gouging can cause fire or explosion.
 Read Owner’s Manual before using or servic-
 Do not cut or gouge near flammables. ing unit.
 Watch for fire; keep extinguisher nearby.  Stop engine and release air pressure before
servicing.
 Use only genuine replacement parts from the
HOT PARTS can cause burns and injury. manufacturer.
 Do not touch hot compressor or air system
parts.
 Let system cool down before touching or ser-
vicing.

1-5. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. WELDING WIRE can cause injury.


 Do not install or place unit on, over, or near  Do not press gun trigger until instructed to do
combustible surfaces. so.
 Do not install unit near flammables.  Do not point gun toward any part of the body,
 Do not overload building wiring − be sure power supply system is other people, or any metal when threading
properly sized, rated, and protected to handle this unit. welding wire.

FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING.


 Use lifting eye to lift unit and properly installed
 Allow cooling period; follow rated duty cycle.
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see  Reduce current or reduce duty cycle before
Specifications). starting to weld again.
 Lift and support unit only with proper equipment  Do not block or filter airflow to unit.
and correct procedures.
 If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit. STATIC (ESD) can damage PC boards.
 Put on grounded wrist strap BEFORE handling
OVERHEATING can damage motors. boards or parts.
 Use proper static-proof bags and boxes to
 Turn off or unplug equipment before starting or store, move, or ship PC boards.
stopping engine.
 Do not let low voltage and frequency caused by
low engine speed damage electric motors.
TILTING OF TRAILER can cause injury.
 Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.  Use tongue jack or blocks to support weight.
 Properly install welding generator onto trailer
FLYING SPARKS can cause injury. according to instructions supplied with trailer.

 Wear a face shield to protect eyes and face.


 Shape tungsten electrode only on grinder with
READ INSTRUCTIONS.
proper guards in a safe location wearing proper
face, hand, and body protection.
 Read Owner’s Manual before using or servic-
 Sparks can cause fires — keep flammables away. ing unit.
 Use only genuine replacement parts from the
MOVING PARTS can cause injury. manufacturer.
 Perform engine and air compressor mainte-
 Keep away from moving parts. nance and service according to this manual
 Keep away from pinch points such as drive and the engine/air compressor (if applicable)
rolls. manuals.

OM-236 949 Page 4


H.F. RADIATION can cause interference. ARC WELDING can cause interference.
 High-frequency (H.F.) can interfere with radio  Electromagnetic energy can interfere with
navigation, safety services, computers, and sensitive electronic equipment such as micro-
communications equipment. processors, computers, and computer-driven
 Have only qualified persons familiar with equipment such as robots.
electronic equipment perform this installation.  Be sure all equipment in the welding area is
 The user is responsible for having a qualified electrician electromagnetically compatible.
promptly correct any interference problem resulting from the  To reduce possible interference, keep weld cables as short as
installation. possible, close together, and down low, such as on the floor.
 If notified by the FCC about interference, stop using the  Locate welding operation 100 meters from any sensitive elec-
equipment at once. tronic equipment.
 Have the installation regularly checked and maintained.  Be sure this welding machine is installed and grounded
 Keep high-frequency source doors and panels tightly shut, keep according to this manual.
spark gaps at correct setting, and use grounding and shielding to  If interference still occurs, the user must take extra measures
minimize the possibility of interference. such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

1-6. California Proposition 65 Warnings


For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
For Diesel Engines:
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling. defects, and other reproductive harm.

1-7. Principal Safety Standards


Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
from Global Engineering Documents (phone: 1-877-413-5184, website: 416-747-4044, website: www.csa-international.org).
www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec-
Recommended Safe Practices for the Preparation for Welding and Cut- tion, ANSI Standard Z87.1, from American National Standards Institute,
ting of Containers and Piping, American Welding Society Standard 25 West 43rd Street, New York, NY 10036–8002 (phone:
AWS F4.1, from Global Engineering Documents (phone: 212-642-4900, website: www.ansi.org).
1-877-413-5184, website: www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
National Electrical Code, NFPA Standard 70, from National Fire Protec- Work, NFPA Standard 51B, from National Fire Protection Association,
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone: P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-
617-770-3000, website: www.nfpa.org and www. sparky.org). site: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
from Compressed Gas Association, 4221 Walney Road, 5th Floor, and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
Code for Safety in Welding and Cutting, CSA Standard W117.2, from (phone: 1-866-512-1800) (there are 10 Regional Offices—phone for
Canadian Standards Association, Standards Sales, 5060 Mississauga, Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-8. EMF Information


Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them, or using a
Electric And Magnetic Fields cable cover.
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such 3. Do not coil or drape cables around your body.
fields. However, after examining more than 500 studies spanning 17 4. Keep welding power source and cables as far away from
years of research, a special blue ribbon committee of the National
operator as practical.
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power- 5. Connect work clamp to workpiece as close to the weld as
frequency electric and magnetic fields is a human-health hazard.” possible.
However, studies are still going forth and evidence continues to be About Implanted Medical Devices:
examined. Until the final conclusions of the research are reached, you Implanted Medical Device wearers should consult their doctor and the
may wish to minimize your exposure to electromagnetic fields when device manufacturer before performing or going near arc welding, spot
welding or cutting. welding, gouging, plasma arc cutting, or induction heating operations.
To reduce magnetic fields in the workplace, use the following If cleared by your doctor, then following the above procedures is recom-
procedures: mended.

OM-236 949 Page 5


SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_2007−04fre

Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.

2-1. Signification des symboles


DANGER! − Indique une situation dangereuse qui si on  Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
NOTE − Indique des déclarations pas en relation avec des blessures
afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.

2-2. Dangers relatifs au soudage à l’arc


manuel AC avec tension à vide réduite. Dans la plupart des cas, un
Les symboles présentés ci-après sont utilisés tout au long du poste courant continu de type CV est recommandé. Et, ne pas tra-
présent manuel pour attirer votre attention et identifier les ris- vailler seul!
ques de danger. Lorsque vous voyez un symbole, soyez
 Couper l’alimentation ou arrêter le moteur avant de procéder à
vigilant et suivez les directives mentionnées afin d’éviter tout
l’installation, à la réparation ou à l’entretien de l’appareil.
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de Déverrouiller l’alimentation selon la norme OSHA 29 CFR
sécurité énumérées à la section 2-7. Veuillez lire et respecter 1910.147 (voir normes de sécurité).
toutes ces normes de sécurité.  Installer et mettre à la terre correctement cet appareil conformé-
ment à son manuel d’utilisation et aux codes nationaux,
L’installation, l’utilisation, l’entretien et les réparations ne provinciaux et municipaux.
doivent être confiés qu’à des personnes qualifiées.  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
Au cours de l’utilisation, tenir toute personne à l’écart et plus
cordon est raccordée à une prise correctement mise à la terre.
particulièrement les enfants.
 En effectuant les raccordements d’entrée fixer d’abord le conduc-
teur de mise à la terre approprié et contre-vérifier les connexions.
UN CHOC ÉLECTRIQUE peut tuer.  Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chau-
Un simple contact avec des pièces électriques peut des.
provoquer une électrocution ou des blessures graves.  Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est
L’électrode et le circuit de soudage sont sous tension pas endommagé ou dénudé − remplacer le cordon immédiatement
dès que l’appareil est sur ON. Le circuit d’entrée et les circuits s’il est endommagé − un câble dénudé peut provoquer une électro-
internes de l’appareil sont également sous tension à ce moment-là. cution.
En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en  Mettre l’appareil hors tension quand on ne l’utilise pas.
contact avec le fil de soudage sont sous tension. Des matériels mal  Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
installés ou mal mis à la terre présentent un danger. sante ou mal épissés.
 Ne pas enrouler les câbles autour du corps.
 Ne jamais toucher les pièces électriques sous tension.  Si la pièce soudée doit être mise à la terre, le faire directement
 Porter des gants et des vêtements de protection secs ne compor- avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
tant pas de trous. câble de retour.
 S’isoler de la pièce et de la terre au moyen de tapis ou d’autres  Ne pas toucher l’électrode quand on est en contact avec la pièce,
moyens isolants suffisamment grands pour empêcher le contact la terre ou une électrode provenant d’une autre machine.
physique éventuel avec la pièce ou la terre.  Ne pas toucher des porte électrodes connectés à deux machines
 Ne pas se servir de source électrique à courant électrique dans les en même temps à cause de la présence d’une tension à vide dou-
zones humides, dans les endroits confinés ou là où on risque de blée.
tomber.  N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
 Se servir d’une source électrique à courant électrique UNIQUE- conformément à ce manuel.
MENT si le procédé de soudage le demande.
 Porter un harnais de sécurité quand on travaille en hauteur.
 Si l’utilisation d’une source électrique à courant électrique s’avère  Maintenir solidement en place tous les panneaux et capots.
nécessaire, se servir de la fonction de télécommande si l’appareil
 Fixer le câble de retour de façon à obtenir un bon contact métal-
en est équipé.
métal avec la pièce à souder ou la table de travail, le plus près
 Des précautions de sécurité supplémentaires sont requises dans possible de la soudure.
des environnements à risque comme: les endroits humides ou  Isoler la pince de masse quand pas mis à la pièce pour éviter le
lorsque l’on porte des vêtements mouillés; sur des structures mé- contact avec tout objet métallique.
talliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
Une tension DC importante subsiste à l’intérieur
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser des onduleurs après avoir coupé l’alimentation.
les appareils suivants dans l’ordre de préférence: 1) un poste à  Couper l’alimentation du poste et décharger les condensateurs
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste d’entrée comme indiqué dans la Section Maintenance avant de
à souder manuel (électrode enrobée) DC, 3) un poste à souder toucher des composants.
OM-236 949 Page 6
 Porter un casque de soudage approuvé muni de verres filtrants
DES PIÈCES CHAUDES peuvent approprié pour protéger visage et yeux pendant le soudage
provoquer des brûlures graves. (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
 Ne pas toucher à mains nues les parties chau-  Porter des lunettes de sécurité avec écrans latéraux même sous
des. votre casque.
 Prévoir une période de refroidissement avant de  Avoir recours à des écrans protecteurs ou à des rideaux pour
travailler à l’équipement. protéger les autres contre les rayonnements les éblouissements
 Ne pas toucher aux pièces chaudes, utiliser les outils recomman- et les étincelles ; prévenir toute personne sur les lieux de ne pas
dés et porter des gants de soudage et des vêtements épais pour regarder l’arc.
éviter les brûlures.  Porter des vêtements confectionnés avec des matières résistan-
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
DES PIECES DE METAL ou DES LE SOUDAGE peut provoquer un
SALETES peuvent provoquer incendie ou une explosion.
des blessures dans les yeux. Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites peu
 Le soudage, l’écaillement, le passage de la pièce à la brosse en provoquer leur éclatement. Des étincelles peuven
fil de fer, et le meulage génèrent des étincelles et des particules être projetées de l’arc de soudure. La projection d’étincelles, des pièce
métalliques volantes. Pendant la période de refroidissement des chaudes et des équipements chauds peut provoquer des incendies e
soudures, elles risquent de projeter du laitier. des brûlures. Le contact accidentel de l’électrode avec des objet
 Porter des lunettes de sécurité avec écrans latéraux ou un écran métalliques peut provoquer des étincelles, une explosion, un surchauf
facial. fement ou un incendie. Avant de commencer le soudage, vérifier e
s’assurer que l’endroit ne présente pas de danger.
LES FUMÉES ET LES GAZ peu-  Déplacer toutes les substances inflammables à une distance de
vent être dangereux. 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.  Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
 Eloigner votre tête des fumées. Ne pas respirer les fumées.  Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
 À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.  Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
 Si la ventilation est médiocre, porter un respirateur anti-vapeurs fissures et des ouvertures.
approuvé.
 Surveiller tout déclenchement d’incendie et tenir un extincteur à
 Lire et comprendre les spécifications de sécurité des matériaux proximité.
(MSDS) et les instructions du fabricant concernant les métaux, les  Le soudage effectué sur un plafond, plancher, paroi ou séparation
consommables, les revêtements, les nettoyants et les dégraisseurs. peut déclencher un incendie de l’autre côté.
 Travailler dans un espace fermé seulement s’il est bien ventilé ou  Ne pas effectuer le soudage sur des conteneurs fermés tels que
en portant un respirateur à alimentation d’air. Demander toujours à des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
un surveillant dûment formé de se tenir à proximité. Des fumées et préparés correctement conformément à AWS F4.1 (voir les nor-
des gaz de soudage peuvent déplacer l’air et abaisser le niveau mes de sécurité).
d’oxygène provoquant des blessures ou des accidents mortels.
 Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
S’assurer que l’air de respiration ne présente aucun danger. peurs inflammables (vapeur d’essence, par exemple).
 Ne pas souder dans des endroits situés à proximité d’opérations  Brancher le câble de masse sur la pièce le plus près possible de la
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et zone de soudage pour éviter le transport du courant sur une
les rayons de l’arc peuvent réagir en présence de vapeurs et for- longue distance par des chemins inconnus éventuels en provo-
mer des gaz hautement toxiques et irritants. quant des risques d’électrocution, d’étincelles et d’incendie.
 Ne pas souder des métaux munis d’un revêtement, tels que l’acier  Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
galvanisé, plaqué en plomb ou au cadmium à moins que le revête- lées.
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit  En cas de non utilisation, enlever la baguette d’électrode du porte-
bien ventilé, et en portant un respirateur à alimentation d’air. Les électrode ou couper le fil à la pointe de contact.
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.  Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
LES ACCUMULATIONS DE GAZ ris- revers, des chaussures hautes et un couvre chef.
quent de provoquer des blessures ou  Avant de souder, retirer toute substance combustible de vos po-
même la mort. ches telles qu’un allumeur au butane ou des allumettes.
 Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-
 Fermer l’alimentation du gaz protecteur en cas ce d’étincelles incandescentes ni de flammes.
de non utilisation.
 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
 Veiller toujours à bien aérer les espaces confinés ou se servir Ne pas augmenter leur puissance; ne pas les ponter.
d’un respirateur d’adduction d’air homologué.
 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
LES RAYONS DE L’ARC peuvent extincteur à proximité.
provoquer des brûlures dans les
yeux et sur la peau. LE BRUIT peut affecter l’ouïe.
Le rayonnement de l’arc du procédé de soudage Le bruit des processus et des équipements peut affec
génère des rayons visibles et invisibles intense l’ouïe.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le  Porter des protections approuvés pour les ore
soudage. les si le niveau sonore est trop élevé.

OM-236 949 Page 7


 Placer les bouteilles debout en les fixant dans un support station-
LES CHAMPS MAGNETIQUES peuvent naire ou dans un porte-bouteilles pour les empêcher de tomber ou
affecter des implants médicaux. de se renverser.

 Porteur de simulateur cardiaque ou autre im-  Tenir les bouteilles éloignées des circuits de soudage ou autres
plants médicaux, rester à distance. circuits électriques.
 Les porteurs d’implants doivent d’abord consulter leur médecin  Ne jamais placer une torche de soudage sur une bouteille à gaz.
avant de s’approcher des opérations de soudage à l’arc, de sou-  Une électrode de soudage ne doit jamais entrer en contact avec
dage par points, de gougeage, du coupage plasma ou de chauf- une bouteille.
fage par induction.
 Ne jamais souder une bouteille pressurisée − risque d’explosion.
 Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
Si des BOUTEILLES sont endomma- tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
gées, elles pourront exploser.
 Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
Des bouteilles de gaz protecteur contiennent du gaz bouteille.
sous haute pression. Si une bouteille est endomma-
gée, elle peut exploser. Du fait que les bouteilles de gaz font  Maintenir le chapeau de protection sur la soupape, sauf en cas
normalement partie du procédé de soudage, les manipuler avec d’utilisation ou de branchement de la bouteille.
précaution.  Utiliser les équipements corrects, les bonnes procédures et suffi-
samment de personnes pour soulever et déplacer les bouteilles.
 Protéger les bouteilles de gaz comprimé d’une chaleur excessive,  Lire et suivre les instructions sur les bouteilles de gaz comprimé,
des chocs mécaniques, des dommages physiques, du laitier, des l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
flammes ouvertes, des étincelles et des arcs. Association) mentionné dans les principales normes de sécurité.

2-3. Dangers existant en relation avec le moteur

 Seules des personnes qualifiées sont autorisées à enlever les por-


L’EXPLOSION DE LA BATTERIE tes, panneaux, recouvrements ou dispositifs de protection pour
peut RENDRE AVEUGLE. effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.
 Toujours porter une protection faciale, des gants  Pour empêcher tout démarrage accidentel pendant les travaux
en caoutchouc et vêtements de protection lors d’entretien, débrancher le câble négatif (−) de batterie de la borne.
d’une intervention sur la batterie.
 Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
 Arrêter le moteur avant de débrancher ou de brancher les câbles
 Remettre en place les panneaux ou les dispositifs de protection et
de batterie.
fermer les portes à la fin des travaux d’entretien et avant de faire
 Eviter de provoquer des étincelles avec les outils en travaillant sur démarrer le moteur.
la batterie.  Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
 Ne pas utiliser le poste de soudage pour charger les batteries ou mise en route accidentelle du moteur.
des véhicules de démarrage rapide.  Bloquer le volant moteur pour éviter sa rotation lors d’une interven-
 Observer la polarité correcte (+ et −) sur les batteries. tion sur le générateur.

 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en DES PIÈCES CHAUDES peuvent
dernier lieu. provoquer des brûlures graves.
 Ne pas toucher à mains nues les parties chau-
LE CARBURANT MOTEUR peut pro- des.
voquer un incendie ou une explosion.  Prévoir une période de refroidissement avant de
 Arrêter le moteur avant de vérifier le niveau de travailler à l’équipement.
carburant ou de faire le plein.  Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
 Ne pas faire le plein en fumant ou proche d’une source d’étincel- dés et porter des gants de soudage et des vêtements épais pour
les ou d’une flamme nue. éviter les brûlures.
 Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion. LA VAPEUR ET LE LIQUIDE DE
 Faire attention de ne pas renverser de carburant. Nettoyer tout
REFROIDISSEMENT CHAUD peuvent
carburant renversé avant de faire démarrer le moteur. provoquer des brûlures.
 Jeter les chiffons dans un récipient ignifuge.  Il est préférable de vérifier le liquide de refroi-
 Toujours garder le pistolet en contact avec le réservoir lors du dissement une fois le moteur refroidi pour éviter
remplissage. 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 pré-
DES ORGANES MOBILES peuvent cisé autrement dans la section maintenance du manuel du
provoquer des blessures. moteur).
 Ne pas approcher les mains des ventilateurs,  Si le moteur est chaud et que le liquide doit être vérifié, opérer com-
courroies et autres pièces en mouvement. me suivant.
 Mettre des lunettes de sécurité et des gants, placer un torchon sur
 Maintenir fermés et fixement en place les portes, panneaux, re- le bouchon du radiateur.
couvrements et dispositifs de protection.
 Dévisser le bouchon légèrement et laisser la vapeur s’échapper
 Arrêter le moteur avant d’installer ou brancher l’appareil. avant d’enlever le bouchon.
OM-236 949 Page 8
L’utilisation d’un groupe autonome LA CHALEUR DU MOTEUR peut pro-
à l’intérieur PEUT VOUS TUER EN voquer un incendie.
QUELQUES MINUTES.
 Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces inflammables.
 Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisi-  Tenir à distance les produits inflammables de l’échappement.
ble et inodore.
 JAMAIS utiliser dans une maison ou garage,
même avec les portes et fenêtres ouvertes.
 Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.

L’ACIDE DE LA BATTERIE peut pro- LES ÉTINCELLES À L’ÉCHAPPEMENT


voquer des brûlures dans les YEUX et peuvent provoquer un incendie.
sur la PEAU.  Empêcher les étincelles d’échappement du
 Ne pas renverser la batterie. moteur de provoquer un incendie.
 Remplacer une batterie endommagée.  Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
 Rincer immédiatement les yeux et la peau à l’eau.

2-4. Dangers liés à l’air comprimé


RESPIRER L’AIR COMPRIMÉ peut pro- Le METAL CHAUD lors du coupage et
voquer des blessures graves ou causer gougeage plasma peut provoquer un in-
la mort. cendie ou une explosion.
 Ne pas utiliser l’air comprimé pour respirer.  Ne pas couper ou gouger à proximité de pro-
 Utiliser l’air comprimé seulement pour le cou- duits inflammables.
page, gougeage et les outils pneumatiques.  Surveillez et garder un extincteur à proximité.

L’AIR COMPRIMÉ peut provoquer DES PIECES CHAUDES peuvent provo-


quer des brûlures et blessures.
des blessures.
 Ne pas toucher le compresseur ou d’autres
 Porter des lunettes de sécurité approuvées.
éléments du circuit air comprimé chauds.
 Ne pas diriger le jet d’air vers d’autres ou
 Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la
soi-même.
maintenance.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provo- LIRE LES INSTRUCTIONS.
quer des blessures.  Lisez le manuel d’instructions avant l’utilisation
 Relâcher la pression d’air de l’outillage ou du ou la maintenance de l’appareil.
système avant d’effectuer la maintenance,  Arrêter le moteur et relâcher la pression avant
avant de changer ou de rajouter des éléments d’effectuer la maintenance.
ou avant d’ouvrir la purge ou le bouchon de  N’utiliser que les pièces de rechange recommandées par le
remplissage d’huile. constructeur.

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLO- LA CHUTE DE L’APPAREIL peut blesser.


SION.  Utiliser l’anneau de levage pour lever l’appareil et
 Ne pas placer l’appareil sur, au-dessus ou les accessoires correctement installées seuls,
à proximité de surfaces inflammables. PAS les bouteilles de gaz. Ne pas dépasser le
 Ne pas installer l’appareil à proximité de pro- poids nominal maximal de l’œilleton (voir les spé-
duits inflammables. cifications).
 Ne pas surcharger l’installation électrique − s’assurer que l’ali-  Ne lever et ne soutenir l’appareil qu’avec de
mentation est correctement dimensionnée et protégée avant de l’équipement approprié et en suivant les
mettre l’appareil en service. procédures adéquates.
 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.

OM-236 949 Page 9


LE SURCHAUFFEMENT peut endom- UNE REMORQUE QUI BASCULE peut
mager le moteur électrique. entraîner des blessures.
 Arrêter ou déconnecter l’équipement avant de  Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
démarrer ou d’arrêter le moteur.
 Installer convenablement le poste sur la remor-
 Ne pas laisser tourner le moteur trop lentement sous risque d’en-
que comme indiqué dans le manuel s’y rappor-
dommager le moteur électrique à cause d’une tension et d’une fré-
tant.
quence trop faibles.
 Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, LIRE LES INSTRUCTIONS.
s’il y a lieu.
 Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
 N’utiliser que les pièces de rechange recom-
LES ÉTINCELLES VOLANTES ris- mandées par le constructeur.
quent de provoquer des blessures.  Effectuer la maintenance et le service du moteur et du compres-
seur d’air suivant les instructions dans ce manuel ou le manuel
 Porter un écran facial pour protéger le visage et
du moteur/compresseur (si applicable).
les yeux.
 Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette manœuv- LE RAYONNEMENT HAUTE FRÉ-
re est à exécuter dans un endroit sûr lorsque l’on QUENCE (H.F.) risque de provoquer
porte l’équipement homologué de protection du
visage, des mains et du corps. des interférences.
 Les étincelles risquent de causer un incendie − éloigner toute sub-  Le rayonnement haute fréquence (H.F.) peut
stance inflammable. provoquer des interférences avec les équipe-
ments de radio−navigation et de communica-
tion, les services de sécurité et les ordinateurs.
 Demander seulement à des personnes qualifiées familiarisées
DES ORGANES MOBILES peuvent avec des équipements électroniques de faire fonctionner l’instal-
provoquer des blessures. lation.
 Ne pas s’approcher des organes mobiles.  L’utilisateur est tenu de faire corriger rapidement par un électri-
 Ne pas s’approcher des points de coincement cien qualifié les interférences résultant de l’installation.
tels que des rouleaux de commande.  Si le FCC signale des interférences, arrêter immédiatement l’ap-
pareil.
 Effectuer régulièrement le contrôle et l’entretien de l’installation.
LES FILS DE SOUDAGE peuvent  Maintenir soigneusement fermés les portes et les panneaux des
provoquer des blessures. sources de haute fréquence, maintenir les éclateurs à une dis-
 Ne pas appuyer sur la gâchette avant d’en tance correcte et utiliser une terre et un blindage pour réduire les
avoir reçu l’instruction. interférences éventuelles.
 Ne pas diriger le pistolet vers soi, d’autres per-
sonnes ou toute pièce mécanique en enga- LE SOUDAGE À L’ARC risque de
geant le fil de soudage. provoquer des interférences.
 L’énergie électromagnétique risque de provo-
quer des interférences pour l’équipement élec-
L’EMPLOI EXCESSIF peut
tronique sensible tel que les ordinateurs et
SURCHAUFFER L’ÉQUIPEMENT. l’équipement commandé par ordinateur tel que
 Laisser l’équipement refroidir ; respecter le fac- les robots.
teur de marche nominal.  Veiller à ce que tout l’équipement de la zone de soudage soit
 Réduire le courant ou le facteur de marche compatible électromagnétiquement.
avant de poursuivre le soudage.  Pour réduire la possibilité d’interférence, maintenir les câbles de
 Ne pas obstruer les passages d’air du poste. 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 équipe-
LES CHARGES ÉLECTROSTATI- ment électronique sensible.
QUES peuvent endommager les  Veiller à ce que ce poste de soudage soit posé et mis à la terre
circuits imprimés. conformément à ce mode d’emploi.
 Établir la connexion avec la barrette de terre  En cas d’interférences après avoir pris les mesures précéden-
avant de manipuler des cartes ou des pièces. tes, il incombe à l’utilisateur de prendre des mesures supplé-
 Utiliser des pochettes et des boîtes antistatiques pour stocker, mentaires telles que le déplacement du poste, l’utilisation de câ-
déplacer ou expédier des cartes de circuits imprimes. bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
teurs dans la zone de travail.

OM-236 949 Page 10


2-6. Proposition californienne 65 Avertissements
Pour les moteurs à essence :
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal- Les gaz d’échappement des moteurs contiennent des pro-
formations congénitales et, dans certains cas, des cancers. duits chimiques dont l’État de Californie reconnaît qu’ils
(Code de santé et de sécurité de Californie, chapitre 25249.5 provoquent des cancers et des malformations congénitales
et suivants) ou autres problèmes de procréation.

Pour les moteurs diesel :


Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi-
ques dont l’État de Californie reconnaît qu’ils provoquent des Les gaz d’échappement des moteurs diesel et certains de
cancers et des malformations congénitales ou autres leurs composants sont reconnus par l’État de Californie com-
problèmes de procréation. Se laver les mains après manipu- me provoquant des cancers et des malformations
lation. congénitales ou autres problèmes de procréation.

2-7. Principales normes de sécurité


Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org).
Internet : www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protec-
Recommended Safe Practices for the Preparation for Welding and Cut- tion, ANSI Standard Z87.1, de American National Standards Institute,
ting of Containers and Piping, American Welding Society Standard 11 West 43rd Street, New York, NY 10036-8002 (téléphone :
AWS F4.1 de Global Engineering Documents (téléphone : 212-642-4900, site Internet : www.ansi.org).
1-877-413-5184, site Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
National Electrical Code, NFPA Standard 70, de National Fire Protec- Work, NFPA Standard 51B, de National Fire Protection Association,
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
617-770-3000, site Internet : www.nfpa.org). site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, OSHA, Occupational Safety and Health Standards for General Indus-
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
tilly, VA 20151 (téléphone : 703-788-2700, site Internet : and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-
www.cganet.com). tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
Code for Safety in Welding and Cutting, CSA Standard W117.2, de ne de la région 5, Chicago, est 312-353-2220, site Internet :
Canadian Standards Association, 5060 Mississauga, Ontario, Canada www.osha.gov).

2-8. Information EMF


Considérations sur le soudage et les effets de basse fréquence et des 1. Garder les câbles ensemble, les torsader, les scotcher, ou les
champs magnétiques et électriques. recouvrir d’une housse.
Le courant de soudage, pendant son passage dans les câbles de sou- 2. Disposer les câbles d’un côté et à distance de l’opérateur.
dage, causera des champs électromagnétiques. Il y a eu et il y a encore 3. Ne pas courber pas et ne pas entourer pas les câbles autour de
un certain souci à propos de tels champs. Cependant, après avoir exa- votre corps.
miné plus de 500 études qui ont été faites pendant une période de 4. Garder le poste de soudage et les câbles le plus loin possible de
recherche de 17 ans, un comité spécial ruban bleu du National vous.
Research Council a conclu : « L’accumulation de preuves, suivant le 5. Connecter la pince sur la pièce aussi près que possible de la
jugement du comité, n’a pas démontré que l’exposition aux champs
soudure.
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en En ce qui concerne les implants médicaux :
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait Les porteurs d’implants doivent d’abord consulter leur médecin avant
souhaitable de réduire votre exposition aux champs électromagnéti- de s’approcher des opérations de soudage à l’arc, de soudage par
ques pendant le soudage ou le coupage. points, de gougeage, du coupage plasma ou de chauffage par induc-
Pour réduire les champs magnétiques sur le poste de travail, appliquer tion. Si le médecin approuve, il est recommandé de suivre les
les procédures suivantes : procédures précédentes.

OM-236 949 Page 11


SECTION 3 − DEFINITIONS

3-1. Warning Label Definitions

1 Remove unit from shipping


S-177 571
crate. Remove Owner’s
1
+
Manual from unit. Follow
instructions to install muffler.
2 Read Owner’s Manual. Read
labels on unit.
2 3 Use Diesel Fuel only, and fill

+ 4
fuel tank. Leave room for
expansion.
Warning! Watch Out! There
are possible hazards as
3 shown by the symbols. Read
DIESEL Owner’s Manual. Follow
instructions to activate
battery.
4 5 Check oil level. Add oil if
necessary.
6 During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
5 7 After the first 50 hours of
operation, change the oil and
oil filter.
0 − 50 h Std. 200A 0 − 200A

50 h Std.

API CD-MIL L 2104D,


CD/SE, CD/SF
3/96

Notes

Work like a Pro!


Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-236 949 Page 12


3-2. Symbols And Definitions
 Some symbols are found only on CE products.

Fast (Run, Weld/


Stop Engine Slow (Idle) Start Engine
Power)

Starting Aid Engine Oil


Battery (Engine) Engine Oil
(Preheat) Pressure

Check Injectors/ Check Valve Protective Earth


Fuel
Pump Clearance (Ground)

Certified/Trained
Positive Negative Welding Arc
Mechanic

A Amperes
V Volts Panel/Local Remote

Air Temperature Or
Alternating
Engine Engine Output
Current
Temperature

Stick (SMAW) Constant Current MIG (GMAW)


TIG (GTAW)
Welding (CC) Welding

h s 1
Time Hours Seconds Single Phase

3
Read Operator’s Do Not Switch
Three Phase Circuit Protector
Manual While Welding

Engine-Driven,
Electrode
Connection
Work Connection G
3
Three-Phase
Alternator With
Rectifier
Hz Hertz

X Duty Cycle U0 Rated No Load


Voltage (Average) U2 Conventional
Load Voltage
n
Rated Load
Speed

n1 Rated Idle
Speed n0 Rated No Load
Speed I Current I2 Rated Welding
Current

Contactor On Arc Force (Dig) Lift-Arc TIG

OM-236 949 Page 13


SECTION 4 − SPECIFICATIONS

4-1. Weld, Power, And Engine Specifications


Maximum
Welding Weld Output Rated Welding Open- Generator Power Fuel
Engine
Mode Range Output Circuit Rating Capacity
Voltage
400 A, 23 Volts DC,
30% Duty Cycle
Stick: 40 − 410 A 300 A, 32 Volts DC
CC/DC 60% Duty Cycle
TIG: 20 − 410 A
250 A, 30 Volts DC Deutz D2008L04
Single-Phase,
100% Duty cycle Water−Cooled
10 kVA/kW, 91/45 A, 11 gal
60 Four−Cylinder
400 A, 23 Volts DC, 120/240 V AC, (41.6 L)
24.2 HP Diesel Engine
30% Duty Cycle 60 Hz
300 A, 29 Volts DC
CV/DC 14 − 40 V
60% Duty Cycle
250 A, 26.5 Volts DC
100% Duty cycle

4-2. Dimensions, Weights, And Operating Angles


Dimensions
32 in (813 mm)
Height 35-3/4 in (908 mm) G
(to top of lift eye)
26-1/4 in (667 mm)
(mtg. brackets turned in) ! Do not exceed tilt angles or engine could
Width be damaged or unit could tip.
28-3/4 in (730 mm)
(mtg. brackets turned out) ! Do not move or operate
p unit where it
could tip.
tip
Depth 56 in (1422 mm)
A 56 in (1422 mm)
B 54 in (1372 mm) A
B C
C 52 in in (1321 mm)
D 2 in (51 mm)
E 26 in (660 mm)
F 7/8 in (22 mm) 30°

G 27-3/4 in (705 mm) 30°


20°
9/16 in (14 mm) Dia. H
H
4 Holes Front Panel End 20°

Weight
D F
With fuel: 1290 lb (585 kg) E
No fuel: 1208 lb (548 kg)

Lifting Eye Weight Rating:


1500 lb (680 Kg) Maximum

OM-236 949 Page 14


4-3. Volt-Ampere Curves
A. Stick Mode The volt-ampere curves show the
minimum and maximum voltage
100 and amperage output capabilities of
the welding generator. Curves of all
90 other settings fall between the
80 curves shown.

70
60
Max
DC Volts

50
40
30 Min
20

10
0
0 100 200 300 400 500
DC Amperes

B. MIG Mode

100
90
80
70
60
DC Volts

50
Max
40
30
20
Min
10
0
0 100 200 300 400 500
DC Amperes

C. TIG Mode

100
90
80
70
60
DC Volts

Max
50
40
30 Min
20
10
0
0 100 200 300 400 500
DC Amperes

237 301 / 237 300 / 237 302

OM-236 949 Page 15


4-4. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.

2.00
1.75
1.50
U.S. GAL/HR.

1.25
1.00
0.75
0.50
Idle
0.25
0.00
0 50 100 150 200 250 300 350 400
DC WELD AMPERES AT 100% DUTY CYCLE

237 299

4-5. Duty Cycle And Overheating


1 100% Duty Cycle
1 Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.

 This unit is rated for welding at


250 amperes continuously.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.

1000
800
600
WELD AMPERES

500
400
CC
300 CV
250
200

150

100
10 15 20 25 30 40 50 60 80 100
% DUTY CYCLE

217 515

OM-236 949 Page 16


4-6. AC Generator Power Curve
The ac power curve shows the gen-
erator power in amperes available
at the 120 and 240 volt receptacles.
150 300
125 250
100 200
AC VOLTS

75 150
50 100
25 50
0 0
0 20 40 60 80
AC AMPERES IN 240 V MODE
0 40 80 120 160
AC AMPERES IN 120 V MODE
237 303

Notes MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)


22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

OM-236 949 Page 17


SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
! Do not move or operate unit
where it could tip.
! Always securely fasten weld-
Movement ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
ble codes.
NOTICE − Do not install unit where
air flow is restricted or engine may
overheat.
OR OR
 See Section 4-2 for lifting eye rat-
ing.

 See Section 5-2 for mounting


information.

Location/Airflow Clearance

OR OR

18 in
(460 mm)
18 in
18 in (460 mm)
(460 mm)

18 in
18 in (460 mm)
(460 mm)

install3 2008-01 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

OM-236 949 Page 18


5-2. Mounting Welding Generator
! Do not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
Supporting The Unit brackets or bolt unit down.
NOTICE − Do not mount unit by
supporting the base only at the four
mounting brackets. Use cross-
supports to adequately support unit
2 and prevent damage to base.
Mounting Surface:
1 Cross-Supports
2 Mounting Brackets (Supplied)
OR
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brack-
ets.
1 3 1/2 in Bolt And Washer
(Minimum − Not Supplied)
4 3/8-16 x 1 in Screws
(Supplied)
To Bolt Unit In Place:
Remove hardware securing the
1 four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
Mount unit to truck or trailer with 1/2
Using Mounting Brackets in (12 mm) or larger hardware (not
supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
2

Welding Unit In Place


Bolting Unit In Place

2 3

Tools Needed:
9/16 in
install3 2008--01 803 274 / 200 864-A / 803 231

OM-236 949 Page 19


5-3. Grounding Generator To Truck Or Trailer Frame

! Always ground generator


frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
! Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
! Bed liners, shipping skids,
and some running gear insu-
late the welding generator
from the vehicle frame. Al-
ways connect a ground wire
from the generator equip-
1 2 ment grounding terminal to
bare metal on the vehicle
GND/PE frame as shown.
! If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.
1 Equipment Grounding
Terminal (On Front Panel)
3 2 Grounding Cable (Not
Supplied)
3 Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.

 Electrically bond generator


frame to vehicle frame by met-
al-to-metal contact.

rot_grnd 2008-01 − 800 652-D

5-4. Rating Label Location


1 Rating Label − Typical
Locate rating label on unit. Label pro-
1
vides information such as weld output
ratings, generator ratings, and engine
information.

 Evidence of label tampering voids


warranty.

rot_label 2008-01 − 804 712

OM-236 949 Page 20


5-5. Installing Exhaust Pipe
! Stop engine and let cool.
 Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.

Tools Needed:
1/2 in 803 582 / Ref. 217 357-A

Notes

Work like a Pro!


Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-236 949 Page 21


5-6. Activating The Dry Charge Battery (If Applicable)
! Always wear a face shield,
rubber gloves and protective
clothing when working on a
battery.
3
Remove battery from unit.
1 Vent Caps
2 2 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
1 3 Well
Fill each cell with electrolyte to
bottom of well (maximum).
! Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
4 Battery Charger
! Read and follow all instruc-
tions supplied with battery
charger.
5 5 Amperes For 30 Minutes
Charge Time
5 6 30 Amperes For 12 Minutes
4 Charge Time
Charge battery. Disconnect charg-
ing cables and install battery.

 When electrolyte is low, add


only distilled water to cells to
5A maintain proper level.

+
6


Tools Needed: 30 A
drybatt 12008−01 − S-0886

5-7. Connecting The Battery


! Connect negative (−) battery
cable last.

 Close door after connecting


battery.

Tools Needed:
1/2 in

805 177-A / Ref. 217 357-D / S-0756-C

OM-236 949 Page 22


5-8. Engine Prestart Checks

Check radiator coolant


level when fluid is low in
recovery tank.

Full
Full

Diesel
Capacity:
6 qt (5.7 L)

Coolant Recovery Tank

Hot Full

Cold Full

Full
805 177-A

 Check all engine fluids daily. Engine stops if fuel level is low. freeze to mixture if using the unit in tempera-
tures below −34° F (−37° C).
Engine must be cold and on a level surface. Oil
Unit is shipped with 20W break-in oil.
Automatic shutdown system stops engine if Keep radiator and air intake clean and free
After fueling, check oil with unit on level sur- of dirt.
oil pressure is too low or coolant tempera- face. If oil is not up to full mark on dipstick,
ture is too high. add oil (see maintenance label).
NOTICE − Incorrect engine temperature
 This unit has a low oil pressure shut- can damage engine. Do not run engine with-
down switch. However, some condi- Coolant
out a properly working thermostat and ra-
tions may cause engine damage before diator cap.
the engine shuts down. Check oil level Check coolant level in radiator before start-
often and do not use the oil pressure ing unit the first time. If necessary, add cool-
shutdown system to monitor oil level. ant to radiator until coolant level is at bottom  To improve cold weather starting:
of filler neck.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust Use Preheat switch (see Section 6-1).
Check coolant level in recovery tank daily.
pipe during run-in, see Section 10.
If necessary, add coolant to recovery tank Keep battery in good condition. Store
Fuel until coolant level is between Cold Full and battery in warm area.
NOTICE − Do not use gasoline. Gasoline Hot Full levels. If recovery tank coolant level
will damage engine. was low, also check coolant level in radiator. Use fuel formulated for cold weather
The unit is shipped with enough fuel to pre- Add coolant if level is below bottom of radia- (diesel fuel can gel in cold weather).
vent air from entering fuel system. Add fresh tor filler neck. Contact local fuel supplier for fuel in-
diesel fuel before starting (see engine main- formation.
tenance label for fuel specifications). Leave Unit is shipped with an engine coolant mix-
filler neck empty to allow room for ture of water and ethylene glycol base anti- Use correct grade oil for cold weather
expansion. freeze rated to −34° F (−37° C). Add anti- (see Section 8-2).

OM-236 949 Page 23


5-9. Connecting To Weld Output Terminals

Stick and TIG Welding MIG and FCAW Welding


For Stick and TIG welding Direct Current Elec- For MIG and FCAW welding Direct Current
trode Positive (DCEP), connect electrode Electrode Positive (DCEP) connect wire feed-
holder cable to CC (Stick/TIG) terminal on er cable to CV (Wire) terminal on right and
right and work cable to Work/Negative (−) ter- work cable to Work/Negative (−) terminal on
minal on left. left. Use Process/Contactor switch to select
type of weld output (see Section 6-3).
For Direct Current Electrode Negative
(DCEN), reverse cable connections. For Direct Current Electrode Negative
(DCEN), reverse cable connections.
Use Process/Contactor switch to select type
of weld output (see Section 6-3).

! Stop engine.
1 Work/Negative (−) Weld Output Terminal
2 CV (wire) Weld Output Terminal
3 CC (Stick/TIG) Weld Output Terminal
! Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
4 Weld Output Terminal
5 Supplied Weld Output Terminal Nut
6 Weld Cable Terminal
7 Copper Bar
Remove supplied nut from weld output termi-
nal. Slide weld cable terminal onto weld output
terminal and secure with nut so that weld cable
terminal is tight against copper bar. Do not
place anything between weld cable termi-
nal and copper bar. Make sure that the sur- 2
faces of the weld cable terminal and cop- 3
per bar are clean. 1

Tools Needed:

3/4 in

1 2 3

7
4

Do not place
anything between
weld cable terminal
and copper bar.

Correct Installation Incorrect Installation

803 562 / 803 778-A

OM-236 949 Page 24


5-10. Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
! Stop engine before
connecting to weld
output terminals. 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
! Do not use worn, dam- (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
aged, undersized, or
poorly spliced cables.
10 − 60% 60 − 100%
Welding
Duty Duty 10 − 100% Duty Cycle
Amperes
Cycle 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)

2 ea. 2/0 2 ea. 2/0


250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0


300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0


350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0


400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)

* This chart is a general guideline and may not suit all applications. If cables overheat, 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-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

Notes

OM-236 949 Page 25


5-11. Connecting To Remote 14 Receptacle RC14

Socket* Socket Information

A 24 volts ac. Protected by sup-


plementary protector CB8.
24 VOLTS AC
B Contact closure to A completes
24 volt ac contactor control
circuit.

C Output to remote control:+10


volts dc in MIG mode; 0 to +10
volts dc in Stick or TIG mode.

REMOTE D Remote control circuit common.


OUTPUT
CONTROL E DC input command signal: 0 to
LDR-14 long +10 volts from min. to max. of
distance remote remote control with Voltage/
(includes 120 V Amperage Adjust control at
receptacle)
p ) max.

115 volts, 10 amperes, 60 Hz


I ac. Protected by supplementary
115 VOLTS AC protector CB7.

Contact closure to I completes


J 115 volt ac contactor control
circuit.
OR
Current feedback: 1 volt per
F 100 amperes.

H Voltage feedback: 1 volt per 10


arc volts.

803 562 GND K Chassis common.

NEUTRAL G Circuit common for 24 and 115


volt ac circuit.

*The remaining sockets are not used.

Notes

Work like a Pro!


Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-236 949 Page 26


Notes

Welding Symbols
Ref. AWS/ANSI A2.4

OM-236 949 Page 27


SECTION 6 − OPERATING WELDING GENERATOR

6-1. Front Panel Controls (See Section 6-2)

8 9
5
6 7 1 2 3 4

217 357-D / 803 563

OM-236 949 Page 28


6-2. Description Of Front Panel Controls (See Section 6-1)

Engine Starting Controls To check fuel level or engine hours when en- 6 Process/Contactor Switch
1 Preheat Switch gine is not running, turn Engine Control switch See Section 6-3 for Process/Contactor
to Run position. switch information.
Use switch to energize starting aid for cold
weather starting (see starting instructions fol- 4 Engine Indicator Light 7 Voltage/Amperage Control
lowing). Light goes on and engine stops if fuel is low, With Process/Contactor switch in any Stick or
2 Engine Control Switch engine temperature exceeds 230° F (110° C) TIG setting, use control to adjust amperage.
or engine oil pressure is below 10 psi (69 With Process/Contactor switch in any Wire
Use switch to start engine, select engine kPa).
speed (if unit has auto idle option), and stop (MIG) position, use control to adjust voltage.
With Voltage/Amperage Adjust Switch in Re-
engine.  Normal engine temperature is 180 - 203 mote position, control limits the remote am-
In Run position, engine runs at weld/power F (82 - 95 C). Normal oil pressure is 30 perage in Stick or TIG mode, but has no effect
speed. In Auto position (optional), engine - 60 psi (207 - 414 kPa). in Wire (MIG) modes.
runs at idle speed at no load and weld speed
with load applied. NOTICE − Do not run engine until trouble is Weld Meters
fixed.
To Start:  Weld meters also work in combination to
Weld Controls display troubleshooting help codes (see
NOTICE − Do not use ether.
5 Remote Control Receptacle Section 8-10).
 If engine does not start, let engine come 8 DC Voltmeter
to a complete stop before attempting re- Use receptacle to connect remote controls,
start. wire feeders, and tools. Voltmeter displays preset voltage (MIG weld-
ing) with contactor off, and actual output volt-
Above 325 F (05 C): turn Engine Control When a remote control is connected to the age with the contactor on. Voltmeter displays
switch to Start. Release Engine Control Remote receptacle, the Auto Sense Remote voltage at the weld output terminals, but not
switch when engine starts. feature automatically switches voltage/am- necessarily the welding arc due to resistance
perage control to the remote control (see Sec- of cable and connections.
Below 325 F (05 C): turn engine control switch tion 5-11).
to Auto position. Push Preheat switch up for To set voltage, turn contactor off and turn Pro-
6 seconds. Turn Engine Control switch to With remote control connected, weld output is cess/Contactor switch to Wire position. Turn
Start. Release Engine Control switch and determined by a combination of front panel V/A control until desired voltage is displayed
Preheat switch when engine starts. and remote control voltage/amperage set- on Voltmeter. When welding is finished, volt-
tings. meter displays weld voltage and then defaults
 Do not operate Preheat switch for more to preset voltage.
than 60 seconds at a time. If no remote control is connected to the Re-
mote receptacle, the front panel Voltage/Am- 9 DC Ammeter
To Stop: turn Engine Control switch to Off perage control adjusts voltage and amper-
position. age. Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
Engine Gauges, Meters, And Lights
 If a remote device connected to Remote output amperage when welding.
 See Section 6-6 for complete fuel/hour Receptacle RC14 is faulty or is discon- To set amperage, turn Process/Contactor
gauge information. nected during operation, the meters dis- switch to Stick or TIG position. Turn V/A con-
play Help 25 (see Section 8-10). Clear trol until desired amperage is displayed on
3 Fuel/Hour Gauge
fault by stopping and restarting the unit or Ammeter. When welding is finished, ammeter
Use gauge to check fuel level, total engine op- by turning Process/Contactor switch to displays weld amperage and then defaults to
erating hours, or hours to oil change. another position. preset amperage.

OM-236 949 Page 29


6-3. Process/Contactor Switch
1 1 Process/Contactor Switch
! Weld output terminals are ener-
gized when Process/Contactor
switch is in a Weld Terminals Al-
ways On position and the engine
is running.
Use switch to select weld process and
weld output on/off control (see table be-
low).
Place switch in Remote On/Off Switch
Required positions to turn weld output on
and off with a device connected to the
Remote 14 receptacle.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use Stick mode for air carbon arc
(CAC-A) cutting and gouging.
When switch is in Stick mode, select one
of four arc drive (dig) settings to provide
additional amperage during low voltage
(short arc length) conditions and prevent
“sticking” electrodes. Turn control from A
to D to increase arc drive (dig) from min
to max.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 6-4).

803 562 / 217 357

Process/Contactor Switch Settings

Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)

Remote On/Off Switch Re-


GTAW With HF Unit, Pulsing
quired −TIG HF Required Or At Remote 14 Receptacle Active
Device, Or Remote Control
Scratch Start

Remote On/Off Switch


Stick (SMAW) With Remote On/Off At Remote 14 Receptacle Active
Required − Stick

Remote On/Off Switch


MIG (GMAW)
Required − CV Feeder At Remote 14 Receptacle Active
w/Constant Speed Feeder
Using Remote

Weld Terminals Always On − MIG (GMAW)


Electrode Hot Active
Wire w/Voltage Sensing Feeder

Stick (SMAW),
Weld Terminals Always On −
Air Carbon Arc (CAC-A) Cutting Electrode Hot Active
Stick
And Gouging

Weld Terminals Always On −


TIG Lift-Arc (GTAW) Electrode Hot Active
TIG Lift-Arc

OM-236 949 Page 30


6-4. Lift-Arct TIG With Crater-Out And Auto-Stopt
Arc Start With Lift-Arc TIG
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted.
Select Lift-Arc at Process/Contac-
tor switch.
Arc Start With Lift-Arc Turn gas on.
1 Touch or scratch.
1 2
2 Lift at any angle.
Touch tungsten electrode to
workpiece at weld start point.
Slowly lift electrode. Arc is started
when electrode is lifted.
Maintain shielding gas coverage
and eliminate tungsten and work-
piece contamination by using
Auto-Crater or Auto-Stop to end
the arc.
Arc End With Crater-Out:

 Momentary contact switch re-


quired to start crater-out.
1 While welding.
Arc End With Crater-Out 2 Close momentary contact
switch to start Crater-out end
(current is reduced).
1 2 3
3 Shielding gas continues until
shut off.
Arc End With Auto-Stop:
1 While welding.
2 Lift torch to start Auto-Stop.
Arc stops.
3 Move torch back down to
maintain gas coverage and
prevent contamination.

OR

Arc End With Auto-Stop

1 2 3

WM Marketing

OM-236 949 Page 31


6-5. Remote Voltage/Amperage Control
1 Remote 14 Receptacle RC14
Connect optional remote control to RC14 (see
Section 5-11).

 When a remote control is connected to the


Remote receptacle, the Auto Sense Re-
1 mote feature automatically switches volt-
age/amperage control to the remote con-
trol. When a device is connected to the Re-
mote receptacle, remote voltage/amper-
age control is always available regardless
of the position of the Process/Contactor
switch.

In Example:
Min = 20 A DC
Max = 205 A DC

Connect Remote Set V/A Control


Control To Remote To Desired Maximum
Adjust Optional Remote Weld Output Using Weld
Receptacle RC14 Control to 100% Meters
Set TIG or STICK Process

Max (205 A DC)

Min (20 A DC)

Adjust Optional Remote


Control to desired
weld output

Weld meters will always


show the combined main
and remote control setting
Adjust Optional Remote and machine welds at
Control to desired nominal output setting of
Connect Remote the meter.
Control To Remote weld output
Receptacle RC14 Weld meters show preset
output when not welding.
Set WIRE Process

0774 / Ref.217 357−B / 803 562

OM-236 949 Page 32


6-6. Fuel/Hour Gauge Descriptions

OM-236 949 Page 33


SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Receptacles

1 2 3 4 5 6

217 357-A

1 120 V 20 A AC (shown)
Receptacle RC5 and/or GFCI1
 At least once a month, run engine at overload. If CB5 opens, the receptacles do
not work. Place CB5 switch in On position
weld/power speed and press test but-
2 120 V 20 A AC GFCI (shown) to reset circuit breaker.
ton to verify GFCI is working properly.
Receptacle RC6 and/or GFCI2
RC11 supplies 60 Hz single-phase power  If a supplementary protector continues
3 240 V 50 A AC at weld/power speed. Maximum output to open, contact Factory Authorized
Receptacle RC11 from RC11 is 10 kVA/kW. Service Agent.
RC5 / 6 and GFCI1 / 2 supply 60 Hz single-
phase power at weld/power speed. Recep-
4 Supplementary Protector CB4  Generator power decreases as weld
tacle configuration varies depending on 5 Supplementary Protector CB6 output increases.
machine model and serial number.
6 Supplementary Protector CB5 Combined output of all receptacles is limit-
Maximum output from these receptacles is ed to the 10 kVA/kw rating of the generator.
2.4 kVA/kW. CB4 protects RC6 / GFCI2 and CB6 pro-
tects RC5 / GFCI1 from overload. If a sup- EXAMPLE: If 15 A is drawn from each 120
If a ground fault is detected, GFCI Reset plementary protector opens, the receptacle V receptacle , only 26 A is available at the
button pops out and receptacle does not does not work. Press button to reset. 240 V receptacle:
work. Check for faulty equipment plugged
in receptacle. Press button to reset GFCI Supplementary protector CB5 protects re- 2 x (120 V x 15 A) + (240 V x 26 A) =
receptacle. ceptacles and the generator winding from 10.0 kVA/kW

OM-236 949 Page 34


SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Routine Maintenance
! Stop engine before maintaining.

Recycle engine
 See Engine Manual and Maintenance Label
for important start-up, service, and storage
fluids.
information. Service engine more often if
used in severe conditions.

 = Check  = Change  = Clean  = Replace Reference


* To be done by Factory Authorized Service Agent
Every Section 5-8,
8 8-6
Hours

 Coolant Level  Fuel Level  Oil Level  Oil, Fuel Spills


Every
50
Hours

 Weld Terminals
Every Section 8-3
100
Hours

 Battery Terminals  Air Cleaner Hoses  Air Cleaner Element


Every Engine
250 1/2 in.
(13 mm) Manual,
Hours Section 8-4

 Unreadable Labels  Fan Belt Tension  Oil  Oil Filter  Spark Arrestor
Every
500
Hours

 Weld Cables  Fuel Filter  Inline Fuel Filter  Radiator Thermostat


Every Section 5-8,
FUEL
1000 8-8, 8-6 and
OR
Hours Engine
Manual
SLUDGE
 Radiator Fluid Level  Inside Unit  Valve Clearance*  Drain Sludge

 Slip Rings*
 Brushes*
Every
2000
Hours

 Injectors*

OM-236 949 Page 35


8-2. Maintenance Label

OM-236 949 Page 36


8-3. Servicing Air Cleaner

! Stop engine.
NOTICE − Do not run engine without air
1 3 4 cleaner or with dirty element. Engine
2
damage caused by using a damaged ele-
ment is not covered by the warranty.

 The air cleaner primary element can


be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
Optional risk of unwarrantable equipment
5 damage when determining whether
to clean or replace the primary ele-
ment.

If you decide to clean the primary ele-


ment, we strongly recommend instal-
ling an optional safety element to pro-
vide additional engine protection.
Never clean a safety element. Re-
place the safety element after servic-
ing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
1 Housing
Keep nozzle
2 in (51 mm) 2 Safety Element (Optional)
from element. 3 Primary Element
4 Dust Cap
5 Dust Ejector
To clean air filter:
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
Blow Inspect (if present). Reinstall cap.
NOTICE − Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).

aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 217 357-A

OM-236 949 Page 37


8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler

Tools Needed: ! Stop engine and let cool.

3/8 in 1 Spark Arrestor Muffler


2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3 Exhaust Pipe
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
! Stop engine and let cool.
3 Reinstall cleanout plug.

803 582 / Ref. 214 778-B

8-5. Servicing Engine Cooling System

! Stop engine and let cool.


1 Radiator Draincock
2 Radiator Cap Cover
2 Change coolant according to engine
manual. Add coolant according to Sec-
tion 5-8).
Run engine until engine reaches normal
operating temperature. Check coolant
level in recovery tank. Add coolant if nec-
essary.
After engine cools, check coolant level
again and add coolant if necessary.

805 177-A

OM-236 949 Page 38


8-6. Servicing Fuel And Lubrication Systems

! Stop engine and let cool.


! After servicing, start engine
and check for fuel leaks.
Stop engine, tighten connec-
tions as necessary, and wipe
up spilled fuel.
1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary (Canister) Fuel Filter
5 Secondary (In-Line) Fuel
Filter
6 Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve
through hole in base. See engine
manual and engine maintenance
label for oil/filter change in-
formation.
To replace primary (canister) fuel
filter:
Turn filter counterclockwise. Re-
move filter.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new fil-
ter. Install new filter and turn clock-
wise.
Inspect fuel lines, and replace if
cracked or worn.
To drain water from fuel system:
See engine manual.

6 To replace secondary (in-line)


2 fuel filter:
Note direction of fuel flow as indi-
cated by arrow on side of filter. Re-
move fuel line clamps and discon-
nect fuel lines from fuel filter. Re-
place filter, reconnect fuel lines, and
reinstall clamps.
3 To drain sludge from fuel tank:
! Beware of fire. Do not smoke
and keep sparks and flames
away from drained fuel. Dis-
pose of drained fuel in an en-
vironmentally-safe manner.
Do not leave unit unattended
while draining fuel tank.
5 ! Properly lift unit and secure
in a level position. Use ade-
quate blocks or stands to
support unit while draining
fuel tank.
Attach 1/2 ID hose to drain valve.
Put metal container under drain,
and use screwdriver to open
sludge drain valve. Close valve
4 when sludge has drained. Remove
hose.
Close door.
Tools Needed:

1
805 177-A / 802 490 / Ref. 801 434

OM-236 949 Page 39


8-7. Overload Protection

! Stop engine.

 When a circuit breaker, supple-


mentary protector, or fuse
opens, it usually indicates a
more serious problem exists.
Contact Factory Authorized
Service Agent.
1 Fuse F1
F1 protects the stator exciter wind-
ing from overload. If F1 opens, weld
and generator power is low or stops
entirely.
2 Circuit Breaker CB1 (Not
Shown)
1 3 Supplementary Protector CB2
4 Supplementary Protector CB3
5 Supplementary Protector CB7
6 Supplementary Protector CB8
CB1 protects the engine battery cir-
cuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
when the fault is corrected.
CB2 protects the engine wiring har-
ness. If CB2 opens, the engine will
not crank.
CB3 protects part of the weld control
wiring harness. If CB3 opens, weld
and generator power output stops.
CB7 protects the 115 volt ac output
to remote receptacle RC14. If CB7
3 opens, 115 volt output to RC14
stops.
CB8 protects the 24 volt ac output to
remote receptacle RC14. If CB8
opens, 24 volt output to RC14 stops.

4 Press button to reset supplementary


protector.

5 6

803 562 / 803 566

OM-236 949 Page 40


8-8. Checking Generator Brushes

! Stop engine and let cool.


1 Generator Brush With Spring
Mark and disconnect leads at brush hold-
er cap. Remove brushes.
Replace brushes if damaged or if brush
material is at or near minimum length.

5/16 in. (8 mm)


Minimum Length

9/16 in. (14.3 mm)


New Length

Replace
Damaged Brushes

Ref 2114 778−D / S−0233−A

8-9. Adjusting Engine Speed

NOTICE − Engine speed adjustment must be done by an engine Factory Authorized Service Agent. Tampering with adjustments may affect engine
warranty.

Notes
MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)


22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

OM-236 949 Page 41


8-10. Voltmeter/Ammeter Help Displays

Use the Voltmeter/Ammeter help


displays to diagnose and correct
fault conditions.

 When a help code is displayed


normally weld output has
stopped but generator power
output may be okay.

 To reset help displays, stop


1 unit and then restart. See item
6 below to reset Help 25 dis-
play.

HL.P 20 1 Help 20 Display


Indicates a failure of meter display
2 module PC2, or the wiring between
PC2 and main control module PC1.
If this display is shown, have Facto-

HL.P 21
ry Authorized Service Agent check
PC1, PC2, and the wiring between
PC1 and PC2.
2 Help 21 Display
3
Indicates thermistor TH1 on the
main rectifier heat sink has failed.

HL.P 22 If this display is shown, have Facto-


ry Authorized Service Agent check
TH1, and the wiring between TH1
4 and PC1.
3 Help 22 Display
Indicates the rectifier heat sink has

HL.P 23 overheated. If this display is shown,


check generator cooling system
and/or reduce duty cycle. Keep en-
5 gine access door closed when run-
ning to maintain proper cooling air
flow past rectifier. Allow unit to cool

25
before restarting. If problem contin-

HL.P ues, have Factory Authorized Ser-


vice Agent check unit.
4 Help 23 Display
Can indicate a complete loss of
generator excitation, auxiliary pow-
er output, and weld output or a fail-
ure of one of the rectifier output
SRCs. If generator output is lost,
see trouble “No generator power or
weld output.” in section 8-11B. If
generator output is okay, have Fac-
tory Authorized Service Agent
check the rectifier SCRs.
5 Help 25 Display
Indicates a remote device con-
nected to Remote Receptacle
RC14 may be faulty. Help 25 is also
displayed whenever a remote de-
vice has been connected to RC14
and then disconnected. Clear fault
by stopping and restarting the unit
or by turning Process/Contactor
switch to another position. If prob-
lem continues, have Factory Autho-
rized Service Agent check the re-
mote device, filter board PC6, and
main control module PC1.

803 562 / 217 357-A

OM-236 949 Page 42


8-11. Troubleshooting

 Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10).

A. Welding

Trouble Remedy

No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at ac receptacles. On/Off Switch Required position and turn remote contactor on (see Section 5-11).

Reset supplementary protector CB7 or CB8 (see Section 8-7). Check for faulty remote device connected
to RC14.

Check and secure connections to Remote Control receptacle RC14 (see Section 5-11).

Check Voltmeter/Ammeter help displays (see Section 8-10).

No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.

Reset supplementary protector CB3. (see Section 8-7).

Check fuse F1, and replace if open (see Section 8-7). If F1 is open, have Factory Authorized Service
Agent check the field excitation circuit.

Check Voltmeter/Ammeter help displays (see Section 8-10).

Have Factory Authorized Service Agent check brushes and slip rings and field excitation circuit.

Erratic weld output. Check and tighten connections inside and outside unit.

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Have Factory Authorized Service Agent check brushes and slip rings.

High weld output. Have Factory Authorized Service Agent check main control module PC1 and hall device HD1.

Low weld output. Check engine speed, and have engine Factory Authorized Service Agent adjust if necessary.

Check fuse F1, and replace if open (see Section 8-7). If F1 is open, have Factory Authorized Service
Agent check the rotor.

Low open-circuit voltage. Check engine speed, and have engine Factory Authorized Service Agent adjust if necessary.

Have Factory Authorized Service Agent check main control module PC1, field excitation circuit, and main
rectifier.

No remote fine amperage control. Repair or replace remote control device.

Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 5-11).

No 24 volt or 115 volt ac output at Re- Reset supplementary protector CB7 (24 volt) or CB8 (115 volt) (see Section 8-7).
mote receptacle RC14.

OM-236 949 Page 43


B. Generator Power

Trouble Remedy
No generator power output at ac recep- Reset receptacle supplementary protector(s) (see Section 7-1).
tacles; weld output okay.

No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
Check fuse F1, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check field
excitation circuit.

Reset supplementary protector CB3 (see Section 8-7).

Check Voltmeter/Ammeter help displays (see Section 8-10).

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power ac re- Have Factory Authorized Service Agent check field excitation circuit.
ceptacles.

Low output at generator power ac recep- Check engine speed, and have engine Factory Authorized Service Agent adjust if necessary.
tacles.

Check fuse F1, and replace if open (see Section 8-7). If F1 is open, have Factory Authorized Service
Agent check the rotor.

C. Engine

Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.

Check battery connections and tighten if necessary.

Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-7).
Have Factory Authorized Service Agent check engine wiring harness and components.

Reset supplementary protector CB2 (see Section 8-7).

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check Engine Control switch S1, and control relay CR2.

Engine cranks but does not start. Check fuel level.

Check battery and replace if necessary. Check engine charging system according to engine manual.

Have Factory Authorized Service Agent check control relay CR1, fuel solenoid FS1, and the fuel
pump.

Air in fuel system. See engine manual.

Engine hard to start in cold weather. Use Preheat switch (see Section 6-1).

Keep battery in good condition. Store battery in warm area off cold surface.

Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.

Use correct grade oil for cold weather (see Section 8-2).

Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow
plug.

Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 5-8 ).

Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-7).
Reset supplementary protector CB2 (see Section 8-7). Have Factory Authorized Service Agent check
engine alternator, engine harness, fuel valve, and the fuel pump.

Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, inte-
grated rectifier SR2, fuel valve, and the fuel pump.

See engine manual.

OM-236 949 Page 44


Trouble Remedy
Engine slowly stopped and cannot be Check fuel level.
restarted.

Check engine air and fuel filters (see Sections 8-3 and 8-6).

See engine manual.

Battery discharges between uses. Turn Engine Control switch off when unit is not running.

Clean top of battery with baking soda and water solution; rinse with clear water.

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months).

Engine idles, but does not come up to Have Factory Authorized Service Agent check fuel/hour gauge and current transformer CT1.
weld speed (units with idle option only).

Engine does not run at idle speed Have Factory Authorized Service Agent check fuel/hour gauge, and control relay CR4.
(units with idle option only).

Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 10).
wetstacking occurs.

Notes

OM-236 949 Page 45


SECTION 9 − ELECTRICAL DIAGRAMS

Figure 9-1. Circuit Diagram For Welding Generator


OM-236 949 Page 46
236 892-A

OM-236 949 Page 47


SECTION 10 − RUN-IN PROCEDURE
run_in1 2007−04

10-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts
weld output and do not exceed duty
cycle or equipment damage may
occur.
1 Welding Generator
2 Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
NOTICE − Do not idle engine longer
than necessary. Piston rings seat
faster if engine runs at weld/power
rpm, and the welding generator is
kept loaded during run-in.
1
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for addition-
al engine run-in information.

OM-236 949 Page 48


10-2. Run-In Procedure Using Load Bank
! Stop engine.
! Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
4 ! Keep exhaust and pipe away
from flammables.
2 NOTICE − Do not perform run-in
procedure at less than 20 volts weld
1 output and do not exceed duty
cycle or equipment damage may
occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe correct
polarity.
Start engine and run for several
3 minutes.
Set load bank switches and then
adjust generator A/V control so
load equals rated voltage and
current of generator (see name-
plate, rating label, or the specifi-
cations section in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.
! Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0683

OM-236 949 Page 49


10-3. Run-In Procedure Using Resistance Grid

! Stop engine.
! Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
6
! Keep exhaust and pipe away
from flammables.
2
NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty
cycle or equipment damage may
occur.
1 Resistance Grid
Use grid sized for generator rated
1 output.
Turn Off grid.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connec-
tors (polarity is not important).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
3 5 shown, if not provided on generator.
Start engine and run for several
minutes.
Set grid switches and then ad-
just generator A/V control so
load equals rated voltage and
4 current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).
+ Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.
! Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0684

OM-236 949 Page 50


SECTION 11 − GENERATOR POWER GUIDELINES
 The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
11-1. Selecting Equipment

1 Generator Power Receptacles


− Neutral Bonded To Frame
2 3-Prong Plug From Case
Grounded Equipment
3 2-Prong Plug From Double
1 Insulated Equipment
 Be sure equipment has double
insulated symbol and/or word-
2 ing on it.
! Do not use 2-prong plug un-
less equipment is double in-
sulated.

OR

gen_pwr 2008−01 − ST-800 577

11-2. Grounding Generator To Truck Or Trailer Frame

! Always ground generator


frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
! Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
1 Equipment Grounding
Terminal (On Front Panel)
2 Grounding Cable (Not
Supplied)
3 Metal Vehicle Frame
Connect cable from equipment
1 2 ground terminal to metal vehicle
frame. Use #10 AWG or larger
GND/PE
insulated copper wire.

 Electrically bond generator


frame to vehicle frame by met-
al-to-metal contact.
! Bed liners, shipping skids,
3 and some running gear insu-
late the welding generator
from the vehicle frame. Al-
ways connect a ground wire
from the generator equip-
ment grounding terminal to
bare metal on the vehicle
frame as shown.
! If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.

800 652-D

OM-236 949 Page 51


11-3. Grounding When Supplying Building Systems

1 Equipment Grounding
1 2 Terminal
GND/PE 2 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3 Ground Device
 Use ground device as stated in
electrical codes.
! Ground generator to system
earth ground if supplying
2 3 power to a premises (home,
shop, farm) wiring system.
! Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.

ST-800 576-B

11-4. How Much Power Does Equipment Require?

1 Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2 Non-Resistive Load
Equipment with a motor is a non-re-
3 sistive load and requires approxi-
VOLTS 115 mately six times more power while
2 AMPS 4.5 starting the motor than when running
1 Hz 60 (see Section 11-8).
3 Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
3 Example 1: If a drill uses 4.5 am-
peres at 115 volts, calculate its run-
ning 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 Ex-
ample 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623

OM-236 949 Page 52


11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Split Phase 1/8 HP 800 300
1/6 HP 1225 500
1/4 HP 1600 600
1/3 HP 2100 700
1/2 HP 3175 875
Capacitor Start-Induction Run 1/3 HP 2020 720
1/2 HP 3075 975
3/4 HP 4500 1400
1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000
5 HP 23300 6000
7-1/2 HP 35000 8000
10 HP 46700 10700
Fan Duty 1/8 HP 1000 400
1/6 HP 1400 550
1/4 HP 1850 650
1/3 HP 2400 800
1/2 HP 3500 1100

11-6. Approximate Power Requirements For Farm/Home Equipment


Farm/Home Equipment Rating Starting Watts Running Watts
Stock Tank De-Icer 1000 1000
Grain Cleaner 1/4 HP 1650 650
Portable Conveyor 1/2 HP 3400 1000
Grain Elevator 3/4 HP 4400 1400
Milk Cooler 2900 1100
Milker (Vacuum Pump) 2 HP 10500 2800
FARM DUTY MOTORS 1/3 HP 1720 720
Std. (e.g. Conveyors, 1/2 HP 2575 975
Feed Augers, Air 3/4 HP 4500 1400
Compressors) 1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
High Torque (e.g. Barn 1-1/2 HP 8100 2000
Cleaners, Silo Unloaders, 5 HP 23300 6000
Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000
10 HP 46700 10700
3-1/2 cu. ft. Mixer 1/2 HP 3300 1000
High Pressure 1.8 Gal/Min 500 PSI 3150 950
Washer 2 gal/min 550 PSI 4500 1400
2 gal/min 700 PSI 6100 1600
Refrigerator or Freezer 3100 800
Shallow Well Pump 1/3 HP 2150 750
1/2 HP 3100 1000
Sump Pump 1/3 HP 2100 800
1/2 HP 3200 1050

OM-236 949 Page 53


11-7. Approximate Power Requirements For Contractor Equipment
Contractor Rating Starting Watts Running Watts
Hand Drill 1/4 in 350 350
3/8 in 400 400
1/2 in 600 600
Circular Saw 6-1/2 in 500 500
7-1/4 in 900 900
8-1/4 in 1400 1400
Table Saw 9 in 4500 1500
10 in 6300 1800
Band Saw 14 in 2500 1100
Bench Grinder 6 in 1720 720
8 in 3900 1400
10 in 5200 1600
Air Compressor 1/2 HP 3000 1000
1 HP 6000 1500
1-1/2 HP 8200 2200
2 HP 10500 2800
Electric Chain Saw 1-1/2 HP, 12 in 1100 1100
2 HP, 14 in 1100 1100
Electric Trimmer Standard 9 in 350 350
Heavy Duty 12 in 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in 400 400
Flood Lights HID 125 100
Metal Halide 313 250
Mercury 1000
Sodium 1400
Vapor 1250 1000
Submersible Pump 400 gph 600 200
Centrifugal Pump 900 gph 900 500
Floor Polisher 3/4 HP, 16 in 4500 1400
1 HP, 20 in 6100 1600
High Pressure Washer 1/2 HP 3150 950
3/4 HP 4500 1400
1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900
2-1/2 HP 1300 1300

OM-236 949 Page 54


11-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements


Motor Start G H J K L M N P
Code
KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

1 Motor Start Code


2 Running Amperage
3 Motor HP
4 4 Motor Voltage
AC MOTOR 2
1 To find starting amperage:
VOLTS 230 AMPS 2.5
3 CODE M Hz 60 Step 1: Find code and use table to
find kVA/HP. If code is not listed,
HP 1/4 PHASE 1 multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amper-
age (see example).
Welding generator amperage out-
put must be at least twice the
motor’s running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amper-
age required for a 230 V, 1/4 HP mo-
tor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624

11-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of


Generator Output
1
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.
2 5 Second Rule
2
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-236 949 Page 55


11-10. Typical Connections To Supply Standby Power

! Have only qualified persons


perform these connections
according to all applicable
1 2 3 4 codes and safety practices.
Fused ! Properly install and ground
Utility Welding
Disconnect this equipment according to
Electrical Transfer Switch Generator
Switch its Owner’s Manual and na-
Service Output
(If Required) tional, state, and local codes.

 Customer-supplied equipment
is required if generator will sup-
ply standby power during
emergencies or power out-
5
ages.
1 Utility Electrical Service
Essential
Loads 2 Transfer Switch (Double-Throw)
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is re-
stored.
Install correct switch (customer-
supplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customer-
supplied) if required by electrical
code.
4 Welding Generator Output
Generator output voltage and wir-
ing must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low volt-
age and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the prem-
ises. If generator does not produce
enough output to meet all require-
ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 11-4).

OM-236 949 Page 56


11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current
Load (Watts) 4 6 8 10 12 14
(Amperes)

5 600 350 (106) 225 (68) 137 (42) 100 (30)

7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)

10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)

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
Load (Watts) 4 6 8 10 12 14
(Amperes)

5 1200 700 (213) 450 (137) 225 (84) 200 (61)

7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)

10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)

15 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-236 949 Page 57
SECTION 12 − PARTS LIST
 Hardware is common and not
available unless listed.

Wirng harnesses are listed at


the end of parts section.

6
7 16
15
8 17
18
9

10 19

11 26
5 20

12 25
14 21
13
22 23 24

4 (Fig.15−5)
3
2
1

100
101
110 102

109 (Fig.15−2) 108 94 93


95
96 92
97
91
98
99
107 (Fig.15−2) 90
89

103
105
104

106

Figure 12-1. Main Assembly


OM-236 949 Page 58
33
32
30
34
29
31
28 44
42 43

35 37
41
27 36
40
39
76
77 38
73
78 75 45
72
74 47
48 49 46
50
87 51
59
79 (Fig 12−4) 70 58
63 52
71 64 53
69 65 62 57
88 86 68
61 56 54
85 60
80
66
67
84 55
83 81

82

805 178-A

OM-236 949 Page 59


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-1. Main Assembly

. . . 1 . . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1


. . . 2 . . . . . R3 . . . . . 213027 . . Resistor, WW Tap 300 W 40 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 217070 . . Bracket, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . Figure 12-5 . . Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 181853 . . Insulator, Screw (For Rectifier Mtg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . 214742 . . Capacitor Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213489 . . . . Bus Bar, Capacitor Bank Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213490 . . . . Bus Bar, Capacitor Bank Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . C10 . . . . 163535 . . . . Capacitor, Elctlt 16000 Uf 60 Vdc Can 1.75 Dia . . . . . . . . . . . . . . . . . . . 6
. . . 6 . . . . . . . . . . . . . +213488 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . PC1 . . . . 231705 . . Module, Main Control/Scr Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . T1 . . . . . 232445 . . Xfmr, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 232425 . . Bracket, Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . Z1 . . . . . 213929 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192303 . . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . TE1, TE2 . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 12 . . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 213602 . . Gasket, Exhaust Outlet Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 214753 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 213493 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 228746 . . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 234544 . . Ftg, Hose Brs Barbed Elbow M 5/16 Tbg X 1/4 Npt . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . *213858 . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 228779 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 237666 . . Ftg, Hose Brs Splice 5/32 Tbg X 1/4 Tbg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 227687 . . Pipe, Exhaust Flexible Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 183314 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 24 . . . . . . . . . . . . . . 212604 . . Baffle, Air Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 226018 . . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 212605 . . Pipe, Exhaust Blue Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 233088 . . Label, Danger Using A Generator Indoors Can Kill You In Minutes . . . . . 1
. . . 28 . . . . . . . . . . . . . +213470 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . 29 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 222513 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 201851 . . Cover, Radiator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 214604 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 192041 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 213472 . . Keeper, Latch Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 213471 . . Bracket, Cover Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . . 217387 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 213503 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . +212607 . . Shroud, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 233256 . . Radiator, W/14# Cap 3 Row Core 1.25 In Inlet/Outlet (Includes) . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187120 . . . . Cap, Radiator Pressure 14lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 212603 . . Baffle, Air Upper Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . +225400 . . Upright, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 225412 . . Cover, Radiator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 220295 . . Bracket, Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 190190 . . Tank, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 228396 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 228246 . . Label, Diesel Engine Maintenance Deutz 2008L04 . . . . . . . . . . . . . . . . . . 1

OM-236 949 Page 60


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-1. Main Assembly (Continued)

. . . 49 . . . . . . . . . . . . . . 237013 . . Label, Hour/Fuel Meter Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 50 . . . . . . . . . . . . . . 199592 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . +213487 . . Door, Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 52 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 3
. . . 53 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 54 . . . . . . . . . . . . . . 087341 . . Bumper, Door 1.000 Od X .750 High Rbr 50 Duro W/O . . . . . . . . . . . . . . 2
. . . 55 . . . . . . . . . . . . . . 213486 . . Panel, Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 217698 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . . . . . . . . . . . Washer, Oil Drain (Order Thru Engine Manufacturer) . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 236978 . . Ftg, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 176529 . . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Ft.
. . . 65 . . . . . . . . . . . . . . 197448 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . *228778 . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 213266 . . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 68 . . . . . . . . . . . . . . 237218 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 69 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 2
. . . 70 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 71 . . . . . . . . . . . . . . 227961 . . Hose, Radiator Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 227693 . . Hose, Radiator Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 228780 . . Belt, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 237007 . . Engine, Deutz 2008 (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 228781 . . Switch, Coolant Temp N.c. 110c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 228782 . . Switch, Lubricating Oil Pressure N.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 216811 . . Clip, Nut Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 76 . . . . . . . . . . . . . . 228235 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 197613 . . Air Cleaner, Intake 5.250 In (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197675 . . . . Dust Ejector, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197677 . . . . Cover Assy, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197678 . . . . Body, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦*197679 . . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 227694 . . Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . Figure 12-4 . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . . 213461 . . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 81 . . . . . . . . . . . . . . 213266 . . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . . 227643 . . Tank, Fuel (Includes Fuel Cap And Items Below) . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 181572 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . . 212611 . . . . Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . . 212610 . . . . Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . SENDER . . 235191 . . . . Sender, Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-236 949 Page 61


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-1. Main Assembly (Continued)

. . . 89 . . . . . . . . . . . . . . 213465 . . Bolt, J Stl .312−18 X 7.250 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


. . . 90 . . . . . . . . . . . . . . 213466 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . BATT . . . . 146237 . . Battery, Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . . 213668 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 94 . . . . . . . . . . . . . . 213458 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . . 213483 . . Support, Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . . . . . 224266 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 98 . . . . . . . . . . . . . . 213462 . . Pad, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213670 . . Screw, 500−13x2.25 Hex Flange−hd Gr8 Pln Chem/Phys . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 99 . . . . . . . . . . . . . . 213463 . . Spacer/Snubber, Generator Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . . 213485 . . Support, Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . . 228237 . . Crossmember, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . . . 213460 . . Crossmember, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213600 . . Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 213464 . . Bracket, Battery Locator (In Base − Not Shown) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213506 . . Bracket, Hold−Down Fuel Tank (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . +226104 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . . . . . . . . . 233953 . . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . . . . . . . . . . . . Label, Rating Card (Provide Serial No. When Ordering) . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . . . 220955 . . Panel, Front Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . . . . . . . Figure 12-2 . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . ♦105370 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . . . . . . . Figure 12-3 . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 110 . . . . . . . . . . . . . 213504 . . Tray, Reactor&Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213491 . . Insulator, Capacitor Bank (Applies To Reactor/Rectifier Tray) . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-236 949 Page 62


 Hardware is common and not
available unless listed.

Wirng harnesses are listed at


the end of parts section.

11
10
12
8 9

13
7 14
15

5 16
25
4 23 24
17
24
3 26
1 2 18 27
22
37
36 19
20

35 21

28
29
30

31
34
32

33

803 684-C

Figure 12-2. Panel, Front w/Components

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 108)

... 1 . . . . . . . . . . . . . . 097926 . . Knob, Pointer 2.375 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . 1


... 2 . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . 1
... 6 ........................ Nameplate, Control (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . PC6 . . . . 229949 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . CB7, CB8 . . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 2
... 9 . . . . . . . . . . . . . . 213655 . . Panel, Front Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-236 949 Page 63


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-2. Panel, Front w/Components (Continued)

... 10 . . . . . . . . . . . . . . 214543 . . Enclosure, Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


... 11 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 4
... 12 . . . . PC2 . . . . 214660 . . Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . R1 . . . . . 214760 . . Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . . 1
... 14 . . . . . R2 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . S4 . . . . . 021467 . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . . 1
... 16 . . . . . S1 . . . . . 212436 . . Switch, Ignition 4 Position (Includes Knob) . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . . . . . . . . . . . . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 18 . . . . . . . . . . . . . . 010381 . . Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 19 . C13, 14, 15 . 128750 . . Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . . 3
... 20 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 21 . . . . RC11 . . . . 182954 . . Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . . . . 1
... 22 ........................ Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . . 1
... 23 . . . . . . . . . . . . . . 213509 . . Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . RC5,6 . . . 214918 . . Rcpt,Str Dx Grd 2p3w 20a 125v *5−20r (Order By Model & Serial No.)
... 24 . . GFCI1, 2 . . 151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi (Order By Model & Serial No.)
... 25 . . C11, C12 . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2
... 26 . . CB4, CB6 . . 093996 . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 2
... 27 . . . . CB5 . . . . 203026 . . Supplementary Protector, Man Reset 2p 50a 240vac . . . . . . . . . . . . . . . . 1
... 28 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 29 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 30 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 31 ........................ Nameplate, Weld Terminal (Order By Model & Serial No.) . . . . . . . . . . . . . 1
... 32 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 33 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 34 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 35 . . . . . . . . . . . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 36 . . FUEL/HM . . 232111 . . Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 37 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-236 949 Page 64


5
 Hardware is common and not
available unless listed. 4
Wirng harnesses are listed at
the end of parts section. 3
2

1
8

10

805 180-A
11
Figure 12-3. Control Panel

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 12-3. Control Panel (Figure 12-1 Item 109)

... 1 . . . . . . . . . . . . . . 220981 .. Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


... 2 . . . . . . . . . . . . . . 129524 .. Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . 2
... 3 . . . . CR2 . . . . 214876 .. Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . CB1 . . . . 190374 .. Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . CR1 . . . . 223710 .. Relay, Encl 12vdc Dpst−no 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . 046432 .. Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . F1 . . . . . 085874 .. Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . CR4 . . ♦090104 .. Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 1
... 9 . . . . CR3 . . . . 197325 .. Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . SR1,2,4,5 . . 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 11 . . CB2, CB3 . . 083432 .. Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 2
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-236 949 Page 65


 Hardware is common and not 5
available unless listed.

Wirng harnesses are listed at 4


the end of parts section.
7
3 6
1

8
9

10

11

12
13
14

20 19 18
17
16 805 179-A
15

Figure 12-4. Generator


Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-4. Generator (Figure 12-1 Item 79)

... 1 . . . ROTOR . . . 212474 . . Rotor, Generator 4 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


... 2 .............. 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 192600 . . . . Fan, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 159918 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 227060 . . Adapter, Engine Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 083883 . . Washer, Lock .402idx0.709odx.087t Stl Pln Split10mm . . . . . . . . . . . . . . . 6
... 7 .............. 601965 . . Screw, 375−16x1.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 6
... 8 .............. 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 6
... 9 .............. 192686 . . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . 6
... 10 .............. 212641 . . Stud, Stl .375−16 1.625x 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 11 . . STATOR . . 235013 . . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 .............. 160943 . . Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 .............. 167788 . . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . 4
... 14 .............. 218552 . . Brush, Assembly 2 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 .............. 047879 . . . . Bar, Retaining Brushholder 2 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 .............. 161306 . . . . Cap, Brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 17 .............. 126984 . . . . Brush w/Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 18 .............. 005614 . . . . Holder, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 19 .............. 125548 . . . . Holder, Brush Elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 .............. 158832 . . Screw, 010−32x .50 Hex Hd−slt Stl Pld Sq Cone Sems . . . . . . . . . . . . . . 2
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-236 949 Page 66


 Hardware is common and not
available unless listed. 6
1
Wirng harnesses are listed at
the end of parts section.

3
2

10

9
803 685-A

Figure 12-5. Rectifier Assembly

Item Dia. Part


No. Mkgs. No. Description Quantity

Figure 12-5. Rectifier Assembly (Figure 12-1 Item 4)

.................... 217081 . . Rectifier, Assembly (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


... 1 .............. 211984 . . . . Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . MOD1,2,3 . . 218296 . . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . MOD4,5,6 . . 218292 . . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 4 .............. 212602 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 212639 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 6 .............. 212601 . . . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . TH1 . . . . 213930 . . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . C1−6 . . . . 215611 . . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . . . C7,8,9 . . . 048420 . . . . Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 3
. . . 10 . . . . . . . . . . . . . . 217085 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 181853 . . Insulator, Screw (For Mounting Rectifier) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-236 949 Page 67
 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo-
nents separately or as part of the associated wiring harness.

Item Dia. Part


No. Mkgs. No. Description Quantity

Wiring Harnesses

.................... 231122 . . Harness, Engine (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . . . . . . . . . S4 . . . . . 021467 . . . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . 1
. . . . . . . . SR1, SR2 . . 035704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . CB1 . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB2, CB3 . . 083432 . . . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . 2
. . . . . . . . . . CR3 . . . . 197325 . . . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR2 . . . . 214876 .. Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . R4 . . . . . 217335 . . . . Resistor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 212116 . . . . Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 212117 . . . . Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG1 . . . . 214932 . . . . Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
.................... 214934 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . For S1 . . . 211292 . . . . Conn, Pack 4p 1row Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . For S1 . . . 211293 . . . . Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . . 1
.................... 129524 . . . . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . 2

.................... 217002 . . Harness, Weld Control (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . . . . . . . . PLG2 . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 214951 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal . . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 214934 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG8 . . . . 147992 . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 193184 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG7 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 215261 . . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . . 215262 . . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 215265 . . . . Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 215343 . . . . Seal, Plug Deutsch 12−16 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . PLG5 . . . . 113750 . . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
.................... 217000 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 215340 . . . . Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

.................... 214984 . . Harness, Rectifier Cc/Cv (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . . . . . . . PLG11 . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 207716 . . . . Conn, Faston Mini Polarized 2 Skt G1k1 . . . . . . . . . . . . . . . . . . . . . . . . . 6
.................... 207718 . . . . Conn, Faston Mini Polarized 2 Skt G2k2 . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . 217010 . . Harness, Receptacle Auxiliary Power (Includes) . . . . . . . . . . . . . . . . . . 1


. . . . . . . . CB4, CB6 . . 093996 . . . . Supplementary Pro, Man Reset 1p 20a 250vac Fric . . . . . . . . . . . . . . . . 2

OM-236 949 Page 68


Effective January 1, 2008
(Equipment with a serial number preface of LJ or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets, Cables, and
Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
* APT & SAF Model Plasma Cutting Torches
for your local material and workmanship at the time it is shipped by Miller. THIS * Remote Controls
Miller distributor. WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Accessory (Kits)
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
Your distributor also gives replace any warranted parts or components that fail due to such * Canvas Covers
you ... defects in material or workmanship. Miller must be notified in Miller’s True Blue® Limited Warranty shall not apply to:
writing within thirty (30) days of such defect or failure, at which
Service time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings,
reliable response you relays or parts that fail due to normal wear.
Miller shall honor warranty claims on warranted equipment listed (Exception: brushes, slip rings, and relays are
need. Most replacement below in the event of such a failure within the warranty time
covered on Bobcat, Trailblazer, and Legend
parts can be in your periods. All warranty time periods start on the delivery date of the
models.)
hands in 24 hours. equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American 2. Items furnished by Miller, but manufactured by others,
Support distributor or eighteen months after the equipment is shipped to such as engines or trade accessories. These items are
Need fast answers to the an International distributor. covered by the manufacturer’s warranty, if any.
tough welding questions? 1. 5 Years Parts — 3 Years Labor 3. Equipment that has been modified by any party other
Contact your distributor. than Miller, or equipment that has been improperly
* Original main power rectifiers only to include SCRs,
The expertise of the diodes, and discrete rectifier modules installed, improperly operated or misused based upon
distributor and Miller is industry standards, or equipment which has not had
there to help you, every 2. 3 Years — Parts and Labor
reasonable and necessary maintenance, or equipment
step of the way. * Transformer/Rectifier Power Sources which has been used for operation outside of the
* Plasma Arc Cutting Power Sources specifications for the equipment.
* Process Controllers MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Semi-Automatic and Automatic Wire Feeders USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated)
In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Engine Driven Welding Generators replacement; or, where authorized in writing by Miller in
(NOTE: Engines are warranted separately by the appropriate cases, (3) the reasonable cost of repair or
engine manufacturer.) replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
3. 1 Year — Parts and Labor Unless Specified depreciation based upon actual use) upon return of the goods at
* Motor Driven Guns (w/exception of Spoolmate customer’s risk and expense. Miller’s option of repair or
Spoolguns) replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
* Positioners and Controllers
Miller. Therefore no compensation or reimbursement for
* Automatic Motion Devices transportation costs of any kind will be allowed.
* RFCS Foot Controls TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Induction Heating Power Sources, Coolers, and PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
Electronic REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Controls/Recorders DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Water Coolant Systems (Non-Integrated)
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
* Flowgauge and Flowmeter Regulators (No Labor) OTHER LEGAL THEORY.
* HF Units ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Grids ANY IMPLIED WARRANTY, GUARANTY OR
* Spot Welders REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Load Banks OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Arc Stud Power Sources & Arc Stud Guns PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Racks OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Running Gear/Trailers MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Plasma Cutting Torches (except APT & SAF PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
Models) FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
* Field Options
(NOTE: Field options are covered under True Blue® Some states in the U.S.A. do not allow limitations of how long an
for the remaining warranty period of the product they implied warranty lasts, or the exclusion of incidental, indirect,
are installed in, or for a minimum of one year — special or consequential damages, so the above limitation or
whichever is greater.) exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
* Bernard-Branded Mig Guns (No Labor) state to state.
* Weldcraft-Branded TIG Torches (No Labor)
In Canada, legislation in some provinces provides for certain
* Subarc Wire Drive Assemblies additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
5. 90 Days — Parts provides specific legal rights, and other rights may be available,
* MIG Guns and Subarc (SAW) Guns but may vary from province to province.
miller_warr 2008-01
Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.


Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters −
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
To locate a Distributor or Service Agency visit FAX: 44 (0) 1204-598066
www.millerwelds.com or call 1-800-4-A-Miller www.MillerWelds.com

Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

PRINTED IN USA © 2008 Miller Electric Mfg. Co. 2008−01

You might also like