Hobart CONTRACTOR 5040P User guide

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OM-491 190 355N

August 2000

Processes

Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A) Cutting and Gouging

Descriptio n

Engine Driven Welding Generator

Contractor 5040P

Visit our website at

www.HobartWelders.com

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From Hobart to You

Thank you and congratulations on choosing Hobart. 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.

This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you

protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Hobart you can count on years of reliable service with proper maintenance. And if for some reason the unit

Hobart is registered to the ISO 9001 Quality System Standard.

needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Hobart Welders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-877-Hobart1.

Hobart offers a Technical Manual which provides more detailed service and parts information for your unit. T o obtain a Technical Manual, contact your local distributor. Y our distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMA W-P.

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WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section

25249.5 et seq.)

WARNING

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

CALIFORNIA Proposition 65

Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The following terms are used interchangeably throughout this manual:

Stick = SMAW TIG = GTA W MIG = GMAW

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 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISA TION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers existant en relation avec le moteur 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Weld, Power, And Engine Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Dimensions, Weights, And Operating Angles 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Volt-Ampere Curves For CC Models 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Volt-Ampere Curves for CC/CV Models 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Fuel Consumption 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Duty Cycle And Overheating 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. AC Auxiliary P o w e r C u r v e 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Optional AC Power Plant Curves 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – INSTALLATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Installing Welding Generator (See Sections 4-2 And 4-3) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Using Lifting Eye 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Mounting Welding Generator 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Installing Muffler 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Activating The Dry Charge Battery (If Applicable) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Connecting The Battery 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Engine Prestart Checks 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Connecting To Weld Output Terminals 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Selecting Weld Cable Sizes 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 20. . . . . . . . . . . . .

4-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models 21. . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS 22. . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Front Panel Controls For CC Models (See Section 5-2) 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Description Of Front Panel Controls For CC Models (See Section 5-1) 23. . . . . . . . . . . . . . . . .

5-3. Remote Amperage Control On CC Models (Optional) 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS 25. . . . . . . . . . . . . . . . . . . . . .

6-1. Front Panel Controls For CC/CV Models (See Section 6-2) 25. . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1) 26. . . . . . . . . . . . . .

6-3. Process/Contactor Switch On CC/CV Models 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) 28. . . . . . . . . . . . . . . . . . . . .

SECTION 7 – OPERATING AUXILIAR Y EQUIPMENT 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. 120 Volt And 240 Volt Receptacles 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only) 30. . . . . . . . . . . . . . . . . .

SECTION 8 – MAINTENANCE & TROUBLESHOOTING 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Routine Maintenance 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Maintenance Label 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Servicing Air Cleaner 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 34. . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Adjusting Engine Speed 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Servicing Fuel And Lubrication Systems 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Overload Protection 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8. Diagnosing Causes Of Engine Fault Shutdowns 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9. Troubleshooting 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – ELECTRICAL DIAGRAMS 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 – AUXILIARY POWER GUIDELINES 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 – PARTS LIST 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES WARRANTY

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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

rom _nd_11/98

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

 Marks a special safety message.

 Means “Note”; not safety related.

1-2. Arc Welding Hazards

 The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.

 Only qualified persons should install, operate, maintain, and

repair this unit.

 During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input

power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

 Do not touch live electrical parts.  Wear dry, hole-free insulating gloves and body protection.  Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work or ground.

 Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

 Use AC output ONLY if required for the welding process.  If AC output is required, use remote output control if present on

unit.

 Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

 Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

 Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

 When making input connections, attach proper grounding conduc-

tor first – double-check connections.

 Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

 Turn off all equipment when not in use.  Do not use worn, damaged, undersized, or poorly spliced cables.  Do not drape cables over your body.  If earth grounding of the workpiece is required, ground it directly

with a separate cable.

 Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

 Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

 Wear a safety harness if working above floor level.  Keep all panels and covers securely in place.  Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

 Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters.

 Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly of f from t h e weld.

 Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

 Wear approved safety glasses with side shields under your

helmet.

 Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

 Wear protective clothing made from durable, flame-resistant mate-

rial (wool and leather) and foot protection.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

 Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

 If ventilation is poor, use an approved air-supplied respirator.  Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

 Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower th e oxygen level causing injury or death. Be sure the breathing air is safe.

 Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

 Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

OM-491 Page 1

Page 6

WELDING can cause fire or explosion.

HOT PARTS can cause severe burns.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

 Protect yourself and others from flying sparks and hot metal.  Do not weld where flying sparks can strike flammable material.  Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

 Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

 Watch for fire, and keep a fire extinguisher nearby.  Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

 Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see Safety Standards).

 Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

 Do not use welder to thaw frozen pipes.  Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

 Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

 Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

FLYING METAL can injure eyes.

 Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they can throw off slag.

 Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

 Shut off shielding gas supply when not in use.  Always ventilate confined spaces or use ap-

proved air-supplied respirator.

 Allow cooling period before maintaining.  Wear protective gloves and clothing when

working on a hot engine.

 Do not touch hot engine parts or just-welded

parts bare-handed.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

 Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect pacemakers.

 Pacemaker wearers keep away.  Wearers should consult their doctor before

going near arc welding, gouging, or spot welding operations.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

 Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

 Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

 Keep cylinders away from any welding or other electrical circuits.  Never drape a welding torch over a gas cylinder.  Never allow a welding electrode to touch any cylinder.  Never weld on a pressurized cylinder – explosion will result.  Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and associated parts in good condition.

 Turn face away from valve outlet when opening cylinder valve.  Keep protective cap in place over valve except when cylinder is in

use or connected for use.

 Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety Standards.

1-3. Engine Hazards

FUEL can cause fire or explosion.

 Stop engine and let it cool of f before checking or

adding fuel.

 Do not add fuel while smoking or if unit is near

any sparks or open flames.

 Do not overfill tank – allow room for fuel to expand.

 Do not spill fuel. If fuel is spilled, clean up before starting engine.

 Dispose of rags in a fireproof container.

OM-491 Page 2

STEAM AND HOT COOLANT can burn.

 If possible, check coolant level when engine is

cold to avoid scalding.

 Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).

 If the engine is warm, checking is needed, and

there is no overflow tank, follow the next two statements.

 Wear safety glasses and gloves and put a rag over radiator cap.  Turn cap slightly and let pressure escape slowly before completely

removing cap.

Page 7

MOVING PARTS can cause injury.

 Keep away from fans, belts, and rotors.  Keep all doors, panels, covers, and guards

closed and securely in place.

 Stop engine before installing or connecting unit.  Have only qualified people remove guards or covers for maint-

enance and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect

negative ( –) battery cable from battery.

 Keep hands, hair, loose clothing, and tools away from moving

parts.

 Reinstall panels or guards and close doors when servicing is

finished and before starting engine.

 Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

 Block flywheel so that it will not turn while working on generator

components.

BATTERY EXPLOSION can BLIND.

 Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

 Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

 Do not allow tools to cause sparks when working on a battery.  Do not use welder to charge batteries or jump start vehicles.  Observe correct polarity (+ and –) on batteries.  Disconnect negative (–) cable first and connect it last.

BATTERY ACID can BURN SKIN and EYES.

 Do not tip battery.  Replace damaged battery.  Flush eyes and skin immediately with water.

ENGINE EXHAUST GASES can kill.

 Use equipment outside in open, well-ventilated

areas.

 If used in a closed area, vent engine exhaust

outside and away from any building air intakes.

ENGINE HEAT can cause fire.

 Do not locate unit on, over, or near combustible

surfaces or flammables.

 Keep exhaust and exhaust pipes way from

flammables.

EXHAUST SPARKS can cause fire.

 Do not let engine exhaust sparks cause fire.  Use approved engine exhaust spark arrestor in

required areas – see applicable codes.

1-4. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.

 Use lifting eye to lift unit only, NOT running

gear, gas cylinders, trailer, or any other accessories.

 Use equipment of adequate capacity to lift and

support unit.

 If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

FLYING SPARKS can cause injury.

 Wear a face shield to protect eyes and face.  Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper face, hand, and body protection.

 Sparks can cause fires — keep flammables away.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or

stopping engine.

 Do not let low voltage and frequency caused by

low engine speed damage electric motors.

 Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle

where applicable.

OVERUSE can cause OVERHEATING.

 Allow cooling period; follow rated duty cycle.  Reduce current or reduce duty cycle before

starting to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

 Use tongue jack or blocks to support weight.  Properly install welding generator onto trailer

according to instructions supplied with trailer.

READ INSTRUCTIONS.

 Use only genuine MILLER replacement parts.  Perform engine maintenance and service

according to this manual and the engine manual.

OM-491 Page 3

Page 8

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

 High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

 The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

 If notified by the FCC about interference, stop using the

equipment at once.

 Have the installation regularly checked and maintained.  Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

1-5. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society , 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

 Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

 Be sure all equipment in the welding area is

electromagnetically compatible.

 To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

 Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

 Be sure this welding machine is installed and grounded

according t o this manual.

 If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Ma g netic Fields

Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power- frequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from operator as practical.

5. Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

OM-491 Page 4

Page 9

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT

UTILISATION

rom _nd_fre 11/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

 Identifie un message de sécurité particulier.

 Signifie NOTA ; n’est pas relatif à la sécurité.

1-2. Dangers relatifs au soudage à l’arc

 Les symboles présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant e t suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-5. Veuillez lire et respecter toutes ces normes de sécurité.

 L’installation, l’utilisation, l’entretien et les réparations ne

doivent être confiés qu’à des personnes qualifiées.

 Au cours de l’utilisation, tenir toute personne à l’écart et plus

particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les circuits

moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger.

 Ne jamais toucher les pièces électriques sous tension.  Porter des gants et des vêtements de protection secs ne comportant pas

de trous.

 S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens iso-

lants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.

 Ne pas se servir de source électrique àcourant électrique dans les zones

humides, dans les endroits confinés ou là où on risque de tomber.

 Se servir d’une source électrique àcourant électrique UNIQUEMENT si le

procédé de soudage le demande.

 Si l’utilisation d’une source électrique àcourant électrique s’avère néces-

saire, se servir de la fonction de télécommande si l’appareil en est équipé.

 Couper l ’alimentation ou arrêter le moteur avant de procéder à l’installation,

à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

 Installer et mettre à la terre correctement cet appareil conformément à son

manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

 Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que

le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

 En effectuant les raccordements d’entrée fixer d’abord le conducteur de

mise à la terre approprié et contre-vérifier les connexions.

 Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas en-

dommagé ou dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution.

 Mettre l’appareil hors tension quand on ne l’utilise pas.  Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou

mal épissés.

 Ne pas enrouler les câbles autour du corps.  Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct – ne pas utiliser le connecteur de pièce ou le câble de retour.

 Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou

une électrode provenant d’une autre machine.

internes de l’appareil sont également sous tension à ce

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

 N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ

les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

 Porter un harnais de sécurité quand on travaille en hauteur.  Maintenir solidement en place tous les panneaux et capots.  Fixer le c âble de retour de façon à obtenir un bon contact métal-métal avec

la pièce à souder ou la table de travail, le plus près possible de la soudure.

 Isoler la pince de masse quand pas mis à la pièce pour éviter le contact

avec tout objet métallique.

Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation.

 Couper l’alimentation du poste et décharger les condensateurs d’entrée

comme indiqué dans la Section Maintenance avant de toucher des composants.

LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génère

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

 Porter u n casque de soudage muni d’un écran de filtre approprié pour pro-

téger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

 Porter des protections approuvés pour les oreilles si le niveau sondre est

trop élevé.

 Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de

l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

 Porter des vêtements de protection constitué dans une matière durable, ré-

sistant au feu (laine ou cuir) et une protection des pieds.

des rayons visibles et invisibles intenses (ultraviolets et

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.

 Eloigner votre tête des fumées. Ne pas respirer les fumées.  À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de

l’arc pour l’évacuation des fumées et des gaz de soudage.

 Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air

homologué.

 Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-

tions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

 T ravailler dans un espace fermé seulement s’il est bien ventilé ou en por-

tant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.

 Ne pas souder dans des endroits situés à proximité d’opérations de dé-

graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

 Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvani-

sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.

OM-491 Page 5

Page 10

LE SOUDAGE peut provoquer un incendie ou une explosion.

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer

l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

 Se protéger et d’autres personnes de la projection d’étincelles et de métal

chaud.

 Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des

substances inflammables.

 Déplacer toutes les substances inflammables à une distance de 10,7 m de

l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

 Des étincelles et des matériaux chauds du soudage peuvent facilement

passer dans d’autres zones en traversant de petites fissures et des ouvertures.

 Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.  Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-

clencher un incendie de l’autre côté.

 Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-

voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).

 Brancher l e c âble sur la pièce le plus près possible de la zone de soudage

pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.

 Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.  En cas de non utilisation, enlever la baguette d’électrode du porte-électro-

de ou couper le fil à la pointe de contact.

 Porter des vêtements de protection dépourvus d’huile tels que des gants

en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.

 Avant de souder, retirer toute substance combustible de vos poches telles

qu’un allumeur au butane ou des allumettes.

leur éclatement. Des étincelles peuvent être projetées de

DES PARTICULES VOLANTES peuvent blesser les yeux.

 Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent

des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles ris- quent de projeter du laitier.

 Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.

 Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

 Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-

rateur d’adduction d’air homologué.

 Prévoir u n e p ériode de refroidissement avant d’effec-

tuer des travaux d’entretien.

 Porter des gants et des vêtements de protection pour

travailler sur un moteur chaud.

 Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces

récemment soudées.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

 Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

 Porteurs d e stimulateur cardiaque, restez à distance.  Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

 Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des

chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.

 Placer les bouteilles debout en les fixant dans un support stationnaire ou

dans un porte-bouteilles pour les empêcher de tomber ou de se renverser .

 Tenir les bouteilles éloignées des circuits de soudage ou autres circuits

électriques.

 Ne jamais placer une torche de soudage sur une bouteille à gaz.  Une électrode de soudage ne doit jamais entrer en contact avec une bou-

teille.

 Ne jamais souder une bouteille pressurisée – risque d’explosion.  Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et

raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

 Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.  Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation

ou de branchement de la bouteille.

 Lire et suivre les instructions concernant les bouteilles de gaz comprimé,

les équipements associés et les publication P-1 CGA énumérées dans les normes de sécurité.

1-3. Dangers existant en relation avec le moteur

LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.

 Arrêter le moteur avant de vérifier le niveau de carbu-

rant ou de faire le plein.

 Ne pas faire le plein en fumant ou proche d’une sour-

ce d’étincelles ou d’une flamme nue.

 Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son

expansion.

 Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-

rant renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.

OM-491 Page 6

 Toujours vérifier le niveau de liquide de refroidissement dans le vase

 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme

 Mettre des lunettes de sécurité et des gants, placer un torchon sur le

 Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des brûlures.

 Il est préférable de vérifier le liquide de

refroidissement une fois le moteur refroidi pour éviter de se brûler.

d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur).

bouchon du radiateur.

d’enlever le bouchon.

Page 11

DES ORGANES MOBILES peuvent provoquer des blessures.

 Ne pas approcher les mains des ventilateurs, cour-

roies et autres pièces en mouvement.

 Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de

protection.

 Arrêter le moteur avant d’installer ou brancher l’appareil.  Demander seulement à un personnel qualifié d’enlever les dispositifs de

sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de d épannage.

 Pour e m p êcher tout démarrage accidentel pendant les travaux d’entre-

tien, débrancher le câble négatif (–) de batterie de la borne.

 Ne pas approcher les mains, cheveux, vêtements lâches et outils des or-

ganes mobiles.

 Remettre en place les panneaux ou les dipositifs de protection et fermer

les portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.

 Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise

en route accidentelle du moteur.

 Bloquer le volant moteur pour éviter sa rotation lors d’une intervention

sur le générateur.

L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gants en

caoutchouc et vêtements de protection lors d’une in-

tervention sur la batterie.

 Arrêter le moteur avant de débrancher ou de brancher les câbles de

batterie.

 Eviter de provoquer des étincelles avec les outils en travaillant sur la

batterie.

 Ne pas utiliser le poste de soudage pour charger les batteries ou des vé-

hicules de démarrage rapide.

 Observer la polarité correcte (+ et –) sur les batteries.  Débrancher l e c âble négatif (–) en premier lieu. Le rebrancher en dernier

lieu.

L’ACIDE DE LA BATTERIE peut provoquer des br ûlures dans les YEUX et sur la PEAU.

 Ne pas renverser la batterie.  Remplacer une batterie endommagée.  Rincer immédiatement les yeux et la peau à l’eau.

LES GAZ D’ÈCHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels.

 Utiliser l’équipement à l’extérieur dans des zones ou-

vertes et bien ventilées.

 En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappe-

ment du moteur vers l’extérieur à distance des entrées d’air dans les bâti- ments.

LA CHALEUR DU MOTEUR peut provoquer un incendie.

 Ne pas placer l’appareil sur, au-dessus ou à proximité

de surfaces inflammables.

 Tenir à distance les produits inflammables de

l’échappement.

LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

 Utiliser uniquement un pare-étincelles approuvé –

voir codes en vigueur.

1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance

LA CHUTE DE L’APPAREIL peut blesser.

 Utiliser l’anneau de levage uniquement pour soulever

l’appareil lui-même ; sans chariot, de bouteilles de

gaz, remorque, ou autres accessoires.

 Utiliser un équipement de levage de capacité suffi-

sante pour lever l’appareil.



En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.

 Porter un écran facial pour protéger le visage et les

yeux.

 Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de pro-

tecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.

 Les étincelles risquent de causer un incendie – éloigner toute substance

inflammable.

LE SURCHAUFFEMENT peut endommager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant de dé-

marrer ou d’arrêter le moteur.

 Ne pas laisser tourner le moteur trop lentement sous

risque d’endommager le moteur électrique à cause

d’une tension et d’une fréquence trop faibles.

 Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a

lieu.

L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter l e facteur de

marche nominal.

 Réduire le courant ou le facteur de marche avant de

poursuivre le soudage.

 Ne pas obstruer les passages d’air du poste.

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

 Établir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut entraîner des blessures.

 Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.

 Installer convenablement le poste sur la remorque

comme indiqué dans le manuel s’y rapportant.

LIRE LES INSTRUCTIONS.

 Utiliser seulement les pièces de rechange d’origine.  Effecteur la maintenance et la mise en service

d’après le manuel et celui du moteur.

OM-491 Page 7

Page 12

LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences.

 Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipements

de radio–navigation et de communication, les

services de sécurité et les ordinateurs.

 Demander seulement à des personnes qualifiées familiarisées avec des

équipements électroniques de faire fonctionner l’installation.

 L’utilisateur est tenu de faire corriger rapidement par un électricien quali-

fié les interférences résultant de l’installation.

 Si le FCC signale des interférences, arrêter immédiatement l’appareil.  Effectuer régulièrement le contrôle et l’entretien de l’installation.  Maintenir soigneusement fermés les portes et les panneaux des sources

de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.

1-5. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Weld- ing Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme A WS

F4.1, de l ’American Welding Society , 550 N.W. Lejeune Rd, Miami FL 33126

National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

LE SOUDAGE À L’ARC risque de provoquer des interférences.

 L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

 Veiller à ce que tout l’équipement de la zone de soudage soit compatible

électromagnétiquement.

 Pour réduire la possibilité d’interférence, maintenir les câbles de souda-

ge aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).

 Veiller à souder à une distance de 100 mètres de tout équipement élec-

tronique sensible.

 Veiller à ce que ce poste de soudage soit posé et mis à la terre conformé-

ment à ce mode d’emploi.

 En cas d’interférences après avoir pris les mesures précédentes, il in-

combe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil- tres de ligne ou la pose de protecteurs dans la zone de travail.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Règles de s écurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Pra ctices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les ef fets, pour l ’organisme, des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnéti- ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif. 2 Mettre tous les câbles du côté opposé de l’opérateur. 3 Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps. 4 Garder le poste de soudage et les câbles le plus loin possible de

vous. 5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est alors recommandé de respecter les consignes ci–dessus.

OM-491 Page 8

Page 13

SECTION 2 – DEFINITIONS

2-1. Symbols And Definitions

Stop Engine

Starting Aid Battery (Engine)

Check Injectors/

Pump

Positive Negative

Amperes

Fast (Run, Weld/

Power)

Check Valve

Clearance

Volts Panel/Local Remote

Air Temperature Or

Engine

Stick (SMAW)

Welding

Engine

Temperature

Constant Current

(CC)

Slow (Idle) Start Engine

Engine Oil

Pressure

Fuel

Certified/Trained

Mechanic

Output

MIG (GMAW)

Welding

Engine Oil

Protective Earth

(Ground)

Welding Arc

Alternating

Current

TIG (GTAW)

Time

Hours

Three Phase

Electrode

Connection

SECTION 3 – SPECIFICATIONS

NOTE

3-1. Weld, Power, And Engine Specifications

Welding

Mode

CC/DC

CV/DC

(CC/CV

Models

Only)

Weld Output

Range

55 – 600 A

(CC Models)

20 – 600 A

(CC/CV Models)

14 – 40 V

A CC/DC model is shown in this manual.

Rated Welding

Output

400 A, 40 Volts DC,

100% Duty Cycle

500 A, 40 volts DC,

60% Duty Cycle

600 A, 30 Volts DC,

40% Duty Cycle

Read Operator’s

Manual

Work Connection

Maximum

Open-

Circuit

Voltage

Seconds

Circuit Breaker

Auxiliary Power Rating Engine

Standard

Single-Phase,

4 kVA/kW, 34/17 A,

120/240 V AC,

50/60 Hz

Full kVA Option*

Single-Phase/Three-Phase,

12/20 kVA/kW, 50/48A,

120/240 VAC, 60 Hz

*In Addition To Standard

4 kVA/kW Auxiliary Power

Perkins

Perkins 3.1524

Water-Cooled,

Three-Cylinder,

45 HP Diesel Engine

Single Phase

Do Not Switch While Welding

Fuel

Capacity

25 gal

25 gal (95 L)

OM-491 Page 9

Page 14

3-2. Dimensions, Weights, And Operating Angles

Dimensions

Height

60 in (1524 mm)

(to top of muffler)

28-1/2 i n (724 mm)

Width

Depth 64-7/16 i n (1637 mm)

A 64-7/16 in (1637 mm) B 55-7/8 i n (1419 mm) C 46-3/8 i n ( 1178) D 9-1/2 in (241 mm) E 27-1/2 i n (699 mm) F 1 in (25 mm) G 29-1/2 in (743 mm)

(mtg. brackets turned in)

30-3/4 in (781 mm)

(mtg. brackets turned out)

9/16 in (14 mm) Dia.

4 Holes

Weight

w/ Perkins

3.152

No fuel: 1670 lb (758 kg)

w/fuel: 1860 lb (844 kg)

3-3. Volt-Ampere Curves For CC Models

Front Panel End

802 161-A

 Do not exceed tilt angles or engine could

be damaged or unit could tip.

 Do not move or operate unit where it could

tip.

20° 20°

30°

100

DC VOLTS

0 100 200 300 400 500 600

DC AMPERES

The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of al l other settings fall between the curves shown.

Ranges 300–Max

185–425 125–320 85–190 55–90

700

OM-491 Page 10

Ref. 193 017

Page 15

3-4. Volt-Ampere Curves for CC/CV Models

A. Stick Mode

100

DC VOLTS

0 100 200 300 400 500 600 700 800 900 1000

B. MIG Mode

100

DC AMPERES

Ranges 300–Max

185–425 125–320 85–190 55–90

The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of al l other settings fall between the curves shown.

DC VOLTS

0 100 200 300 400 500 600 700 800 900 1000

C. TIG Mode

100

DC VOLTS

MAX

MIN

DC AMPERES

Ranges 60–310

40–200 30–130 20–70

0 50 100 150 200 250 300 350 400 450 500

DC AMPERES

194 364 / 194 365 / 194 366

OM-491 Page 11

Page 16

3-5. Fuel Consumption

1800 RPM

0 50 100 150 200 250 300 350 400 450 500

DC WELD AMPERES AT 100% DUTY CYCLE

The curve shows typical fuel use under weld or power loads.

3-6. Duty Cycle And Overheating

100% Duty Cycle At 400 Amperes

193 093

Duty Cycle is percentage of 10 mi n utes that unit can weld at rated load without overheating.

 Exceeding duty cycle can

damage unit and void warranty.

Continuous Welding

OM-491 Page 12

089 697-D

Page 17

3-7. AC Auxiliary Power Curve

300

150

250

125

200

100

150

AC VOLTS

100

0 5 10 15 20 25 30

AC AMPERES IN 240V MODE

0102030405060

AC AMPERES IN 120V MODE

3-8. Optional AC Power Plant Curves

A. 12 kVA/kW Single-Phase Auxiliary Power Plant (No Weld Load)

280

140

270

135

260

130

250

125

240

120

230

115 110 105 100

95 90

220 210 200 190 180

20 40 60 80 100

AC AMPERES

AC VOLTS

The ac power curve shows the auxiliary power in amperes available at the 120 and 240 volt receptacles.

193 018

The ac power curves show the auxiliary power available in amperes at the single-phase 120/240 volt receptacle or three-phase 240 volt terminals.

B. 20 kVA/kW Three-Phase Auxiliary Power Plant (No Weld Load)

280

260

240

220

AC VOLTS

200

180

0 10203040506070

AC AMPERES

197 472 / 197 473

OM-491 Page 13

Page 18

SECTION 4 – INSTALLATION

4-1. Installing Welding Generator (See Sections 4-2 And 4-3)

Movement Airflow Clearance Location

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

Grounding

4-2. Using Lifting Eye

18 in

(460 mm)

GND/PE

Electrically bond generator frame to vehicle frame by metal-to-metal contact.

18 in

(460 mm)

 Always ground generator

install1 12/99* – Ref. 800 652 / Ref. 800 477-A / 158 936-A / 0854

frame t o vehicle frame to prevent electric shock and static electricity hazards.

1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding

Terminal 4 Grounding Cable Use #10 AWG or larger insulated

copper wire.

 If unit does not have GFCI re-

ceptacles, use GFCI-

protected extension cord.

1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in

place. Lower lifting eye when not needed.

To lock the lifting eye in the upright position, insert a 1/4-20 x 1-1/2 in carriage bolt through slot in bracket and secure with nut (bolt and nut not supplied).

OM-491 Page 14

Tools Needed:

Ref. 802 169-C

Page 19

4-3. Mounting Welding Generator

Welding Unit In Place

Bolting Unit In Place

 Do not weld on base. Weld-

ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.

1 Mounting Bracket 2 1/2 in Bolt And Washer (Not

Supplied)

3 3/8-16 x 1 in Screws

(Supplied)

To Bolt Unit In Place:

Remove hardware securing the four mounting brackets t o the base. Reverse brackets and reattach to base with original hardware.

Mount unit to truck or trailer with 1/2 in (12 mm) hardware (not supplied).

To Weld Unit In Place:

Weld unit to truck or trailer only at the four mounting brackets.

Tools Needed:

9/16 in

4-4. Installing Muffler

Ref. 190 250-A / Ref. 802 169-C

 Stop engine and let cool.  Do not blow exhaust toward

air intakes.

Tools Needed:

1/2 in

Ref. 802 169-B / Ref. 191 631-C

OM-491 Page 15

Page 20

4-5. Activating The Dry Charge Battery (If Applicable)

Remove battery from unit. 1 Eye Protection – Safety

Glasses Or Face Shield 2 Rubber Gloves 3 Vent Caps 4 Sulfuric Acid Electrolyte

(1.265 Specific Gravity) 5 Well Fill each cell with electrolyte to

bottom of well (maximum).

 Do not overfill battery cells.

Wait ten minutes and check electrolyte level. If necessary , add electrolyte to raise to proper level. Reinstall vent caps.

6 Battery Charger

 Read and follow all instruc-

tions supplied with battery

charger.

Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 amperes. Disconnect charging cables and install battery.

 When electrolyte is low, add

only distilled water to cells to

maintain proper level.

5 A For 30 Minutes

30 A For 12 Minutes

OM-491 Page 16

Tools Needed:

–

rubber gloves

glasses

drybatt1 1/98 – 0886

Page 21

4-6. Connecting The Battery

 Connect Negative (–) Cable Last.

Tools Needed:

1/2 in

–

ST-802 168-D / Ref. ST-191 631-C / S-0756-C

Notes

OM-491 Page 17

Page 22

4-7. Engine Prestart Checks

Check radiator coolant level when

fluid is low in recovery tank.

Capacity: w/Overflow

Tank 12 qt (11.4L)

Full

Diesel

Full

 Check all engine fluids daily.

Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. The Automatic shutdown system stops engine if fuel level or oil pressure is too low, or coolant temperature is too high.

 This unit has a low oil pressure shut-

down switch. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level.

Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe during run-in, see Section 10.

Fuel  Do not use gasoline. Gasoline will

damage engine.

The unit is shipped with enough fuel to prevent air from entering fuel system but not enough fuel to prevent low fuel shutdown. Add fresh diesel fuel before starting to pre-

OM-491 Page 18

vent low fuel shutdown (see engine maintenance label for fuel specifications).

Do not run out of fuel or air will enter fuel system and cause starting problems. See engine manual to bleed air from fuel system.

Oil

After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).

Coolant

Check coolant level in radiator before starting unit the first time. If necessary, add coolant to radiator until coolant level is at bottom of filler neck.

Check coolant level in recovery tank daily. If necessary, add coolant to recovery tank until coolant level is between Cold Full a n d Hot Full levels. If recovery tank coolant level was low, also check coolant level in radiator. Add coolant if level is below bottom of radiator filler neck.

Engine coolant is a mixture of water and ethylene glycol base antifreeze. Add anti-

Coolant Recovery Tank

Hot Full

Cold Full

Ref. 802 168-C

freeze to mixture if using the unit in temperatures below –34° F (–37° C).

Keep radiator and air intake clean and free of dirt.

 Incorrect engine temperature can

damage engine. Do not run engine without a properly working thermostat and radiator cap.

 To improve cold weather starting:

Use Starting Aid switch (see Section 5-1 or 6-1).

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

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

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

Page 23

4-8. Connecting To Weld Output Terminals

Tools Needed:

3/4 in

 Stop engine.

1 Positive (+) Weld Output

Terminal

2 Negative (–) Weld Output Ter-

minal

For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect electrode holder cable to Positive (+) terminal on left and work cable to Negative (–) ter- minal on right.

For Direct Current Electrode Negative (DCEN), reverse cable connections.

If equipped with optional polarity switch, connect electrode holder cable to Electrode terminal on left and work cable to Work terminal on right.

For MIG and FCAW welding Direct Current Electrode Positive (DCEP) on CC/CV models, connect wire feeder cable to Positive (+) terminal on left and work cable to Negative (–) terminal on right. Use Process/ Contactor switch to select type of weld output (see Section 6-3).

For Direct Current Electrode Negative (DCEN), reverse cable connections.

If equipped with optional polarity switch, connect wire feeder cable to Electrode terminal on left and work cable to Work terminal on right.

Ref. 802 169-C

4-9. Selecting Weld Cable Sizes

T otal Cable (Copper) Length In Weld Circuit Not Exceeding

Welding

100 ft (30 m) Or Less

Amperes

10 – 60%

Duty Cycle

100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 200 3 2 1 1/0 2/0 3/0 4/0 4/0 250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0 300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0 500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

*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. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E

60 – 100%

Duty Cycle

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

10 – 100% Duty Cycle

350 ft

(105 m)

400 ft

(120 m)

OM-491 Page 19

Page 24

4-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models

1 Remote Amperage Adjust

Receptacle RC13 Connect optional remote control to

RC13 (see Section 5-3).

Ref. 154 862-A / 048 720-K / 802 160-B

OM-491 Page 20

Page 25

4-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models

OUTPUT

Socket* Socket Information

A 24 volts ac. Protected by circuit

24 VOLTS AC

B Contact closure to A completes

C Output to remote control:+10

breaker CB6.

24 volt ac contactor control circuit.

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

New! LDR-14 long

distance remote

(includes 120 V

receptacle)

*The remaining sockets are not used.

REMOTE

D Remote control circuit common.

OUTPUT

CONTROL

115 VOLTS AC

GND

NEUTRAL G Circuit common for 24 and 115

E DC input command signal: 0 to

+10 volts from min. to max. of remote control with Voltage/ Amperage Adjust control at max.

115 volts, 10 amperes, 60 Hz ac. Protected by circuit breaker

CB6.

Contact closure to I completes 115 volt ac contactor control

circuit.

K Chassis common.

volt ac circuit.

OM-491 Page 21

Page 26

SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS

5-1. Front Panel Controls For CC Models (See Section 5-2)

13 18 1914 1210 11

OM-491 Page 22

15 16

191 631-C / 802 311-A

Page 27

5-2. Description Of Front Panel Controls For CC Models (See Section 5-1)

Engine Starting Controls

1 Magnetic Shutdown Switch Use switch during start-up to bypass engine

shutdown system. System stops engine if oil pressure o r fuel level is too low or coolant temperature is too high.

2 Starting Aid Switch Use switch to energize starting aid for cold

weather starting (see starting instructions following).

3 Engine Control Switch Use switch to start engine, select engine

speed ( if unit has auto idle option), and stop engine.

In Run position, engine runs at weld/power speed. In Run/Idle position (optional), engine runs at idle speed at no load and weld speed with load applied.

To Start:

 If engine does not start, let engine come

to a complete stop before attempting restart.

Above 325 F (05 C): turn Engine Control switch to Start while pressing Shutdown switch. Release Engine Control switch when engine starts. Continue holding Shutdown switch until engine indicator lights go out.

Below 3 2 5 F (05 C): turn engine control switch to Run/Idle position. Push Starting Aid switch up for 60 seconds. While still holding Starting Aid switch, press Magnetic Shutdown switch and turn Engine Control switch to Start. Release Engine Control switch and Starting Aid switch when engine starts. Continue holding Shutdown switch until engine indicator lights go out.

To Stop: turn Engine Control switch to Off position.

Engine Indicator Lights

4 Battery Charging Light Light goes on if engine alternator is not charg-

ing battery. Engine continues to run.

 Stop engine and fix trouble if Battery

Charging light goes on.

5 Engine Temperature Light Light goes on and engine stops if engine tem-

perature is above 221 ° F (105° C).

 Stop engine and fix trouble if Engine

Temperature light goes on.

6 Engine Oil Pressure Light Light goes on and engine stops if oil pressure

is below 10 psi (69 kPa). Light goes on momentarily during start-up but goes out when engine reaches normal oil pressure.

 Stop engine and fix trouble if Engine

Oil Pressure light stays on after startup.

7 Fuel Light Light goes on and engine stops if fuel level is

low. Add fuel to resume operation. 8 Engine Hour Meter

Engine Gauges

 To read gauges and engine indicator

lights with engine off, turn Engine Control switch to Run/Idle and press Magnetic Shutdown switch (see Section 8-8).

9 Fuel Gauge Use gauge to check fuel level. To check fuel level when engine is not run-

ning, turn Engine Control switch to Run/Idle position and press Magnetic Shutdown switch.

10 Battery Voltmeter (Optional) Use gauge to check battery voltage and moni-

tor the engine charging system. The meter should read about 14 volts dc when the engine is running, and about 12 volts dc when the engine is stopped.

11 Engine Coolant Temperature Gauge

(Optional)

Normal temperature is 180 - 203° F (82 - 95° C). When equipped with gauge option, engine stops if temperature exceeds 220° F (104° C).

12 Engine Oil Pressure Gauge (Optional) Normal pressure is 30 – 60 psi (207 – 414

kPa). When equipped with gauge option, engine stops if pressure is below 10 psi (69 kPa).

Weld Controls

 Max OCV Control Circuit: This unit has

a max OCV control circuit that resets Amperage Adjust control R1 to maximum when the arc breaks. When an arc is struck, weld outpu t c o n t r o l returns to the R1 front panel or combination front panel/ remote control setting. The Amperage Adjust control adjusts amperage only when welding and does not adjust opencircuit voltage.

The max OCV circuit is disabled when the Stick/TIG Selection switch is in Scratch Start TIG position (see item 15).

13 Ampere Range Switch

 Do not switch under load.

Use switch to select weld amperage range. For most welding applications, use lowest amperage range possible to help prevent arc outages.

14 Amperage Adjust Control Control adjusts amperage within range se-

lected by Ampere Range switch. Weld output would be about 223 A DC with controls set as shown (50% of 125 to 320 A).

 The numbers around the control are for

reference only and do not represent an actual percentage value.

15 Stick/TIG Selection Switch Use switch to disable max OCV circuit for

scratch start TIG welding (see max OCV note under Weld Controls). When switch is in Stick position, the max OCV circuit resets Amperage Adjust Control R1 to maximum when the arc breaks. When switch is in Scratch Start TIG position, max OCV circuit is disabled and OCV changes when the control is adjusted.

16 Amperage Adjust Switch And Remote

Amperage Adjust Receptacle

Connect optional remote control to RC13 (See Section 4-10). Use switch to select front panel or remote amperage control. For remote control, place switch in Remote position and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 4-10 and 5-3).

17 Polarity Switch (Optional)

 Do not switch under load.

Use switch to change weld output. Select either DC Electrode Positive (DCEP) or DC Electrode Negative (DCEN).

Weld Meters

18 DC Voltmeter (Optional) Voltmeter displays voltage at the weld output

terminals, but not necessarily the welding arc due to resistance of cable and connections.

19 DC Ammeter (Optional) Ammeter displays amperage output of the

unit.

OM-491 Page 23

Page 28

5-3. Remote Amperage Control On CC Models (Optional)

1 Remote Amperage Adjust

Receptacle RC13 Connect optional remote control to

RC13 (see Section 4-10).

Example: Combination Remote Amperage Control (Stick)

In Example:

Range = 125 to 320 A DC

Percentage Of Range = 50%

Max = About 223 A DC (50% of 125 to 320)

Max (223 A DC)

Min (87 A DC)

Adjust Optional Remote ControlSet Switches Set Range Set Control

0774 / Ref. 154 862-A / Ref. 181 711-A / 802 160-B

OM-491 Page 24

Page 29

SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS

6-1. Front Panel Controls For CC/CV Models (See Section 6-2)

14 18 1915 1210 11

13 16

192 895-A / 802 311-A

OM-491 Page 25

Page 30

6-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1)

Engine Starting Controls

1 Magnetic Shutdown Switch Use switch during start-up to bypass engine

shutdown system. System stops engine if oil pressure is too low or engine temperature is too high.

2 Starting Aid Switch Use switch to energize starting aid for cold

weather starting (see starting instructions following).

3 Engine Control Switch Use switch to start engine, select engine

speed ( if unit has auto idle option), and stop engine.

In Run position, engine runs at weld/power speed. In Run/Idle position (optional), engine runs at idle speed at no load and weld speed with load applied. Turn to run position if using optional auxiliary power plant (see Section 7-2).

To Start:

 If engine does not start, let engine come

to a complete stop before attempting restart.

To Stop: turn Engine Control switch to Off position.

Engine Indicator Lights

4 Battery Charging Light Light goes on if engine alternator is not charg-

ing battery. Engine continues to run.

 Stop engine and fix trouble if Battery

Charging light goes on.

5 Engine Temperature Light

Light goes on and engine stops if engine temperature is above 221 ° F (105° C).

 Stop engine and fix trouble if Engine

Temperature light goes on.

6 Engine Oil Pressure Light Light goes on and engine stops if oil pressure

is below 10 psi (69 kPa). Light goes on momentarily during start-up but goes out when engine reaches normal oil pressure.

 Stop engine and fix trouble if Engine

Oil Pressure light stays on after startup.

7 Fuel Light Light goes on and engine stops if fuel level is

low. Add fuel to resume operation. 8 Engine Hour Meter

Engine Gauges

 To read gauges and engine indicator

lights with engine off, turn Engine Control switch to Run/Idle and press Magnetic Shutdown switch (see Section 8-8).

9 Fuel Gauge Use gauge to check fuel level. To check fuel level when engine is not run-

ning, turn Engine Control switch to Run/Idle position and press Magnetic Shutdown switch.

10 Battery Voltmeter (Optional) Use gauge to check battery voltage and moni-

tor the engine charging system. The meter should read about 14 volts dc when the engine is running, and about 12 volts dc when the engine is stopped.

11 Engine Coolant Temperature Gauge

(Optional)

Normal temperature is 180 - 203° F (82 - 95° C). When equipped with gauge option, engine stops if temperature exceeds 220° F (104° C).

12 Engine Oil Pressure Gauge (Optional) Normal pressure is 30 – 60 psi (207 – 414

kPa). When equipped with gauge option, engine stops if pressure is below 10 psi (69 kPa).

Weld Controls

13 Process/Contactor Switch

See Section 6-3 for Process/Contactor switch information.

14 Ampere Range Switch

 Do not switch under load.

Use switch to select weld amperage range. Use any range for Stick welding. Read the up-

per set of numbers at each range. Use the lower four ranges for TIG welding.

Read the lower set of numbers at each range. Use the highest range for MIG welding and for

cutting and gouging (CAC-A). For most welding applications, use lowest

amperage range possible to help prevent arc outages.

15 Voltage/Amperage Adjust Control With Process/Contactor switch in any Stick or

TIG setting, use control to adjust amperage within range selected by Ampere Range switch. With Process/Contactor switch in any MIG position, use control to adjust voltage. With Voltage/Amperage Adjust Switch in Remote position, control limits the remote amperage i n TIG mode, but has no ef fect in Stick and MIG modes.

 The numbers around the control are for

reference only and do not represent an actual percentage value.

16 Voltage/Amperage Adjust Switch And

Remote 14 Receptacle

Use switch to select front panel or remote voltage/amperage control. For remote control, place switch in Remote position and connect remote control to Remote 14 receptacle RC14 (see Sections 4-11 and 6-4).

17 Polarity Switch (Optional)

 Do not switch under load.

Use switch to change weld output. Select either DC Electrode Positive (DCEP) or DC Electrode Negative (DCEN).

Weld Meters

18 DC Voltmeter (Optional) Voltmeter displays voltage at the weld output

terminals, but not necessarily the welding arc due to resistance of cable and connections.

19 DC Ammeter (Optional) Ammeter displays amperage output of the

unit.

OM-491 Page 26

Page 31

6-3. Process/Contactor Switch On CC/CV Models

1 Process/Contactor Switch

 Weld output terminals are en-

ergized when Process/Contactor switch is in an Electrode Hot position and the engine is running.

Use switch to select weld process and weld output on/off control (see table below and Section 6-4).

Place switch in Remote positions to turn weld output on and of f with a device connected to the remote 14 receptacle.

Place switch in Electrode Hot positions for weld output to be on whenever the engine is running.

Use Stick position for air carbon arc (CAC-A) cutting and gouging.

 Place switch in Electrode Hot -

Stick position when using optional auxiliary power plant (see Section 7-2).

Process/Contactor Switch Settings

Switch Setting Process Output On/Off Control

Remote – TIG

Remote – Stick Stick (SMAW) With Remote On/Off At Remote 14 Receptacle

Remote – MIG MIG (GMAW) At Remote 14 Receptacle

Electrode Hot – MIG MIG (GMAW) Electrode Hot

Electrode Hot – Stick

Electrode Hot – Scratch

Start TIG

GTA W With HF Unit, Pulsing Device,

Or Remote Control

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting And Gouging

Scratch Start TIG (GTAW) Electrode Hot

At Remote 14 Receptacle

Electrode Hot

OM-491 Page 27

Page 32

6-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)

1 Remote 14 Receptacle RC14 Connect optional remote control to

RC14 (see Section 4-11).

Example: Combination Remote Amperage Control (Stick)

Set V/A

Adjust Switch

Example: Combination Remote Amperage Control (TIG)

Set Remote

Process

Set Range Control Not

Used In Remote

Stick Mode

Process = Stick (Using Remote On/Off)

In Example:

Range = 125 to 320 A DC

Min = 125 A DC

Max = 320 A DC

Max (320 A DC)

Min (125 A DC)

Adjust Optional Remote Control

In Example:

Process = TIG (Using Remote On/Off)

Range = 40 to 200 A DC

Percentage Of Range = 50%

Min = 40 A DC

Max = About 120 A DC (50% of 40 to 200)

Set V/A

Adjust Switch

OM-491 Page 28

Set Remote

Process

Set Range Set Control

Max (120 A DC)

Min (40 A DC)

Adjust Optional Remote Control

0774 / Ref. 192 895-A / 802 169-B

Page 33

SECTION 7 – OPERATING AUXILIARY EQUIPMENT

7-1. 120 Volt And 240 Volt Receptacles

1 120 V 20 A AC GFCI

Receptacle GFCI1

2 240 V 20 A AC Twistlock

Receptacle RC1

Receptacles supply 60 Hz singlephase power at weld/power speed.

If a ground fault is detected, GFCI Reset button pops out and receptacle does not work. Check for faulty tools plugged in receptacle. Press button to reset GFCI1.

 At least once a month, run en-

gine at weld/power speed and press test button to verify GFCI is working properly.

3 Circuit Breaker CB1 4 Circuit Breaker CB2 5 Circuit Breaker CB3 CB1 and CB3 protect RC1 from over-

load. If CB1 or CB3 opens, RC1 does not work. 120 volts may still be present at RC1. Press button to reset breaker.

 Power is still present at the

240 volt receptacle when only one circuit breaker trips.

Unplug power cord before attempting to service accessories or tools.

CB2 protects GFCI1 from overload. If CB2 opens, GFCI1 does not work. Press button to reset breaker.

 If a circuit breaker continues to

open, contact Factory Authorized Service Agent.

 Auxiliary power is not affected by

weld output.

Maximum output is 2.4 kVA/kW from GFCI1 and 4 kVA/kW from RC1. Maximum output from all receptacles is 4 kVA/kW.

EXAMPLE: If 13 A is drawn from RC1, only 7 A i s a v a i lable at GFCI1:

(240 V x 13 A) + (120 V x 7 A) = 4.0 kVA/kW

191 624-A

OM-491 Page 29

Page 34

7-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only)

 Place Process/Contactor switch

in Electrode Hot - Stick position when using auxiliary power plant

Single-Phase Power Connection

(see Section 6-3).

 Place Engine Control switch in

Run position when using auxiliary power plant.

Single-Phase Auxiliary Power

1 120/240 V 50 A Receptacle

RC5

RC5 is connected to the optional auxiliary power plant and supplies 60 Hz single-phase power at weld/power speed. Maximum output from RC5 is 12 kVA/kW. Power available at RC5 is reduced when welding.

2 Circuit Breaker CB7 Circuit breaker CB7 protects single-

phase receptacle RC5 and the load

Three-Phase Power Connection

Remove plug before inserting leads. Reinstall bushing.

 Close panel opening

if no connections are made to power plant.

Rear Of Panel

91 92 93

240V

120V

240V

1-Phase

240V

3-Phase

Output

Volts

Amps

KVA/KW

Engine Speed 1850 RPM

Lead 42 connects to GROUND stud on front of unit.

Jumper 42 i s connected to 90 at factory.

Single Phase

120/240

50 12

Three

Phase

240

48 20

60 HzFrequency

2 12

 Close panel

opening if no connections are made to power plant.

Tools Needed:

wires from overload. If CB7 opens, all auxiliary power plant output stops and the receptacle does not work.

Three-Phase Auxiliary Power

 Stop engine.  Power and weld outputs are

live at the same time. Disconnect or insulate unused cables.

 Have qualified person install ac-

cording to circuit diagram and

Auxiliary Power Guidelines (see Section 11).

Remove auxiliary power panel mounting screws. Tilt panel forward.

3 Lead 93 4 Lead 92

5 Lead 91 6 Lead 42 (Circuit Grounding

Lead) 7 Lead 90 (Neutral) 8 Isolated Neutral Terminal 9 Jumper Lead 42 10 Grounding Terminal Jumper 42 i s connected to lead 90 a t

factory. Jumper 42 may be disconnected from neutral to meet applicable electrical codes.

Lead 42 connects to front panel Ground stud.

11 User-Supplied Leads 12 Circuit Breaker CB7 User

Terminals Connect user-supplied leads to ter-

minals on CB7.

 Circuit breaker CB7 protects

single-phase receptacle RC5

and the load wires from overload.

If CB7 opens, all auxiliary power

plant output stops and the recep-

tacle does not work.

Reinstall auxiliary power panel.

OM-491 Page 30

Ref. 197 399 / 802 332-B

Page 35

SECTION 8 – MAINTENANCE & TROUBLESHOOTING

Note

Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.

8-1. Routine Maintenance

Wipe

Spills.

Clean Air Filter.

See Section 8-3.

Coolant

Full

OIL Full

8 h

50 h

Recycle engine

fluids.

Check Fluid Levels. See Section 4-7.

 Stop engine before maintaining.

 See also Engine Manual and Mainte-

nance Label. Service unit more often if used in severe conditions.

* To be done by Factory Authorized

Service Agent.

FUEL

WATER

Drain Water

From Fuel

System.

Clean And

Tighten

Weld

Terminals.

Replace

Unreadable

Labels.

100 h

Clean An d

Connections.

200 h

250 h

Clean Spark

Arrestor. See

Tighten

Battery

1/2 in.

(13 mm)

Check And

Section 8-4.

Check Belt

Tension.

OM-491 Page 31

Page 36

400 h

Check Radiator

Fluid Level. See

Section 4-7.

Change Fuel

Filters. See

Section 8-6.

500 h

800 h

1000 h

Change Oil. See

Section 8-6.

Repair Or

Replace

Damaged

Cables.

Clean/Set Injectors.*

Change Oil

Filter. See

Section 8-6.

Check

Valve

Clearance.*

Blow Out Or

Vacuum Inside.

During Heavy

Service,

Clean Monthly.

FUEL

SLUDGE

Service Welding Generator

Brushes And Slip Rings. Service

More Often In Dirty Conditions.*

Drain Sludge

From Fuel

Tank. See

Section 8-6.

OM-491 Page 32

Page 37

8-2. Maintenance Label

OM-491 Page 33

Page 38

8-3. Servicing Air Cleaner

 Stop engine.

 Do not run engine without air

cleaner or with dirty element.

1 Evacuator Valve 2 Dust Cap 3 Element 4 Housing Clean or replace element if dirty or

damaged. Replace element yearly or after six cleanings.

To Clean air filter:

Wipe off cap and housing. Remove cap and dump out dust. Wipe dust from inside cap and housing with damp cloth. Remove element and reinstall cap.

 Do not clean housing with air

hose.

Clean element with compressed air. Max. air pressure: 100 psi (690 kPa). Replace element if it has holes or damaged gaskets.

Reinstall element and cap

Blow

Inspect

8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler

3 2

Ref. 187 602-A / 801 964 / Ref. 191 631-C

 Stop engine and let cool.

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.

Reinstall cleanout plug.

Tools Needed:

OM-491 Page 34

3/8 in

802 160-A / Ref. 191 631-C

Page 39

8-5. Adjusting Engine Speed

Engine Speed

(No Load)

Weld/Power

Idle

1850 rpm (61.6 Hz)

1500 rpm (50 Hz)

Standard Models

Models With Automatic Idle (Optional)

 Stop engine and let cool.

Engine speed is factory set and should not require adjustment. After tuning engine, check engine speed with tachometer or frequency meter. See table for proper no load speed. If necessary, adjust speed as follows:

Start engine and run until warm. On CC Models, place Stick/TIG

switch in Stick position. On CC/CV models, turn Process/

Contactor switch to Stick – Electrode Hot position.

Standard Models

1 Adjustment Screw 2 Lock Nut Loosen nuts. Turn screws out sev-

eral turns. 3 Speed Lever Start engine and move lever until

engine runs at weld/power speed. Tighten adjustment screws and lock nuts.

 Do not set engine speed higher

than specified.

Models With Automatic Idle (Optional)

Idle Speed Adjustment

4 Throttle Rod/Plunger 5 Locknut Loosen l o c knut. Place Engine Con-

trol switch in Run/Idle position. Turn throttle rod and plunger until

engine runs at idle speed. Tighten locknut.

 Be sure solenoid plunger pulls

all the way in (“bottoms”) when energized.

Weld/Power Speed Adjustment

6 Engine Weld/Power Speed

Adjustment Screw 7 Locknut Place Engine Control switch in R un

position.

Loosen locknut. Turn screw until engine runs at weld/power speed. Tighten locknut.

 Do not set engine speed higher

than specified.

 Stop engine.

Close door.

Tools Needed:

5/16 in

802 168-C / 802 229-A / Ref. 191 631-C

OM-491 Page 35

Page 40

8-6. Servicing Fuel And Lubrication Systems

 Stop engine and let cool.  After servicing, start engine

and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel.

1 Oil Filter 2 Oil Drain Valve And Hose 3 Oil Fill Cap 4 Fuel Line

5 Primary Fuel Filter (Fuel/

Water Separator)

6 Petcock

7 Secondary Fuel Filter 8 Fuel Tank Sludge Drain Valve

To change oil and filter:

Route oil drain hose and valve through hole in base. See engine manual and engine maintenance label for oil/filter change information.

To drain water from fuel system:

Open primary fuel filter petcock a n d drain water into metal container. Close petcock when water-free fuel flows.

To replace primary fuel filter:

Turn filter counterclockwise. Remove filter.

Fill new filter with fresh fuel. Apply thin coat of fuel to gasket on new filter. Install new filter and turn clockwise. Bleed air from fuel system according to engine manual.

Inspect fuel lines, and replace if cracked or worn.

To replace secondary fuel filter:

See engine manual.

To drain sludge from fuel tank:

Put metal container under drain, and use screwdriver to open sludge drain valve. Close valve when sludge has drained.

Close door.

OM-491 Page 36

Tools Needed:

802 170-A / Ref. 802 168-B / Ref. 801 434

Page 41

8-7. Overload Protection

 Stop engine.

 When a circuit breaker or fuse

opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent.

1 Fuse F1 2 Fuse F2 F1 and F2 protect the stator exciter

winding from overload. If F1 opens, weld and auxiliary power is low or stops entirely . I f F 2 opens, weld output is low or stops entirely. 4 kVA/ kW auxiliary power is still available.

3 Circuit Breaker CB6

(CC/CV Models Only)

4 Circuit Breaker CB10 (Not

Shown) 5 Circuit Breaker CB11 6 Circuit Breaker CB12 7 Circuit Breaker CB13

CB6 protects the 24 and 115 volt ac output to remote receptacle RC14, and 24 volt output to field current regulator board PC1 (CC/CV models only). If CB6 opens, weld output and 24 and 115 volt output to RC14 stops.

CB10 protects the engine battery circuit. If CB10 opens, the engine will not crank. CB10 automatically resets when the fault is corrected.

CB11 protects the engine wiring harness. On CC models, if CB11 opens the max OCV circuit does not work and open circuit voltage is variable at all times (see max OCV note under Weld Controls in Section 5-2). If CB11 opens on CV models, weld output stops (auxiliary power is still available).

CB12 protects the field flashing circuit. If CB12 opens, the generator may not excite at start-up and weld and auxiliary power output may not be available.

CB13 protects the engine shutdown circuit. If CB13 opens, the engine cranks but does not start.

Press button to reset breaker.

802 170-A / Ref. 802 168-C

OM-491 Page 37

Page 42

8-8. Diagnosing Causes Of Engine Fault Shutdowns

Pre-Start Diagnostic Checks

Use the front panel engine lights to help determine the cause of an automatic engine shutdown.

 Correct the cause of the shut-

down before operating the welding generator.

 This unit does not have a bat-

tery charging fault shutdown. The engine continues to run if the Battery Charging Light goes on.

Turn Engine Control Switch To Run/Idle Position While Pressing Magnetic Shut-

down Switch.

Diagnostic Checks While Running

Normal Condition:

Oil Pressure Light On;

Battery Charging, Fuel, And Temperature Lights Off.

If Oil Pressure Light Is Off, See Factory Authorized Service Agent.

If Battery Charging Light Is On, Have Factory Authorized Service Agent

Check Alternator.

If Temperature Light Is On, Correct Cause Of Overheating

(See Engine Manual).

If Engine Is Okay, See Factory Authorized Service Agent.

If Fuel Light Is On, Check Fuel Level.

If Fault Continues, See Factory Authorized Service Agent.

20s

Start Engine (With No Load Applied).

OM-491 Page 38

Continue Pressing Shutdown Switch

Until Engine Lights Go Off.

Engine Lights Go Off As Engine Reaches

Normal Condition:

Normal Operating Condition.

Lights That Stay On After 20 Sec. Indicate

Fault Condition.

Stop Engine And Correct Fault (See Above) If Fault Continues, See Factory Authorized Ser-

vice Agent.

Ref. 191 631-C

Page 43

8-9. Troubleshooting

A. Welding – CC Models

Trouble Remedy

No weld output; auxiliary power output okay.

No weld output or auxiliary power output. Disconnect equipment from auxiliary power receptacles during start-up.

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

High weld output. Check engine speed, and adjust if necessary.

Check position of Ampere Range switch.

Check position of optional polarity switch. Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote

control to Remote Amperage Adjust receptacle RC13 (see Sections 4-10 and 5-1). Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 4-10). Check fuse F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check inte-

grated rectifier SR2 and the rotor. Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (see Section 8-7). Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

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 OCV control circuit.

Low weld output. Check engine speed, and adjust if necessary.

Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor. Low open-circuit voltage. Check engine speed, and adjust if necessary. Maximum weld output only in each

ampere range (with Stick/TIG Selection switch in Stick position).

No remote fine amperage control. Place Amperage Adjust switch in correct position.

Have Factory Authorized Service Agent check control relay CR7.

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 4-10).

Reset circuit breaker CB11 (see Section 8-7). Have Factory Authorized Service Agent check control relay

CR7.

Repair or replace remote control device.

Have Factory Authorized Service Agent check OCV control circuit.

OM-491 Page 39

Page 44

B. Welding – CC/CV Models

Trouble Remedy

No weld output; auxiliary power output okay.

No weld output or auxiliary power output. Disconnect equipment from auxiliary power receptacles during start-up.

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

High weld output. Check position of Ampere Range switch and Voltage/Amperage Adjust control.

Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remot e position and

connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 4-11 and 6-1).

Check position of Ampere Range switch.

Check position of optional polarity switch.

Reset circuit breaker CB11 (see Section 8-7).

Reset circuit breaker CB6 (see Section 8-7). Check for faulty remote device connected to RC14.

Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).

Have Factory Authorized Service Agent check connector board PC6 and connections.

Check fuse F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check

brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor.

Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

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

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent check field current regulator board PC1. Low weld output. Check engine speed, and adjust if necessary.

Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor. Low open-circuit voltage. Check engine speed, and adjust if necessary. No remote fine amperage or voltage

control.

Constant speed wire feeder does not work.

Low CV weld output. Set Ampere Range switch to highest range. Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.

Place Voltage/Amperage Adjust switch in Remote position.

Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).

Repair or replace remote control device.

Reset circuit breaker CB6 (see Section 8-7).

Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).

Repair or replace wire feeder.

Repair or replace remote control device.

Have Factory Authorized Service Agent check field current regulator board PC1.

OM-491 Page 40

Page 45

C. Standard Auxiliary Power

Trouble Remedy

No auxiliary power output; weld output okay.

No auxiliary power or weld output. Disconnect equipment from auxiliary power receptacles during start-up.

High output at auxiliary power receptacles.

Low output at auxiliary power receptacles.

Reset receptacle circuit breakers.

Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, and the rotor.

Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (CC models) or field

current regulator board PC1 (CC/CV models) (see Section 8-7).

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

Check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent adjust auxiliary power field current resistor R3.

Check engine speed, and adjust if necessary.

Check fuse F1, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check inte-

grated rectifier SR1, resistor R3, and capacitor C9.

D. Optional Auxiliary Power Plant

Trouble Remedy

No or low output at optional auxiliary power plant/receptacle RC5 (CC/CV models only).

High output at optional auxiliary power plant/receptacle RC5 (CC/CV models only).

Place Process/Contactor switch in Electrode Hot - Stick position (see Section 6-3).

Reset circuit breaker CB7(see Section 7-2).

Check engine weld/power speed, and adjust if necessary (see Section 8-5).

Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board

PC1.

Check engine weld/power speed, and adjust if necessary (see Section 8-5).

Have Factory Authorized Service Agent check field current regulator board PC1.

E. Engine

Trouble Remedy

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

Check battery connections and tighten if necessary.

Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8-7).

Have Factory Authorized Service Agent check engine wiring harness and components.

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check Engine Control switch S1. Engine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine.

Check fuel level.

Reset circuit breaker CB13 (see Section 8-7). Have Factory Authorized Service Agent check engine-

wiring harness and components.

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

Have Factory Authorized Service Agent check control relay CR2, and fuel solenoid FS1.

Air in fuel system. See engine manual.

OM-491 Page 41

Page 46

Trouble Remedy

Engine starts, but stops when Magnetic Shutdown switch is released.

Engine hard to start in cold weather. Use starting aid switch (see Section 5-1 or 6-1).

Engine suddenly stops. Check fuel, oil, and coolant levels. Automatic shutdown system stops engine if fuel level or oil pressure

Engine slowly stopped and cannot be restarted.

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

When starting engine, continue holding Magnetic Shutdown switch until after engine indicator lights go

out.

Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or cool-

ant temperature is too high (see Sections 4-7 and 8-8).

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).

is too low, or coolant temperature is too high (see Sections 4-7 and 8-8).

See engine manual.

Check fuel level.

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

See engine manual.

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

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months). Engine idles, but does not come up to

weld speed (models with idle option only).

Engine does not run at idle speed (models with idle option only).

Engine uses oil during run-in period; wetstacking occurs.

Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1.

Check for obstructed throttle solenoid.

Place Stick/TIG Selection switch (CC models) or Process/Contactor switch (CC/CV models) in Stick

or MIG position.

Check for obstructed throttle solenoid.

Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.

Dry engine (see Section 10).

OM-491 Page 42

Page 47

Notes

OM-491 Page 43

Page 48

SECTION 9 – ELECTRICAL DIAGRAMS

OM-491 Page 44

Figure 9-1. Circuit Diagram For CC Welding Generator

Page 49

OM-491 Page 45

200 130

Page 50

OM-491 Page 46

Figure 9-2. Circuit Diagram For CC/CV Welding Generator

Page 51

194 008-C

OM-491 Page 47

Page 52

10-1. Wetstacking

SECTION 10 – RUN-IN PROCEDURE

1 Welding Generator Run diesel engines near rated out-

put during run-in period to properly seat piston rings and prevent wetstacking. See nameplate or rating label t o find rated output.

 Do not idle engine longer than

necessary. Piston rings seat faster if engine runs at weld/ power rpm, and the welding generator is kept loaded during run-in.

2 Engine Exhaust Pipe Wetstacking is unburned fuel and

oil in the exhaust pipe and occurs during run-in if the engine is run too long at light load or idle rpm.

If exhaust pipe is coated with a wet, black, tar-like substance, dry the engine using one of the following run-in procedures.

See the engine manual for additional engine run-in information.

run_in1 6/96

OM-491 Page 48

Page 53

10-2. Run-In Procedure Using Load Bank

 Stop engine.  Do not touch hot exhaust

pipe, engine parts, or load bank/grid.

 Keep exhaust and pipe away

from flammables.

1 Load Bank Turn all load bank switches Off. If

needed, connect load bank to 115 volts ac wall receptacle or generator auxiliary power receptacle.

2 Welding Generator Place A/V range switch in maxi-

mum position, A/V control in minimum position, and Output Selector switch (if present) in either DC position.

3 Weld Cables Connect load bank to generator

weld output terminals using proper size weld cables with correct connectors. Observe correct polarity.

Start engine and run for several minutes.

Set load bank switches and then adjust generator A/V control so load equals rated generator output (see nameplate).

Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly.

 Check oil level frequently dur-

ing run-in; add oil if needed.

After one hour (minimum) place A/V control in minimum position, then turn off load bank to remove load. Run engine several minutes at no load.

 Stop engine and let cool.

4 Engine Exhaust Pipe Repeat procedure if wetstacking is

present.

S-0683

OM-491 Page 49

Page 54

10-3. Run-In Procedure Using Resistance Grid

 Stop engine.  Do not touch hot exhaust

pipe, engine parts, or load bank/grid.

 Keep exhaust and pipe away

from flammables.

1 Resistance Grid Use grid sized for generator rated

output. Turn Off grid. 2 Welding Generator Place A/V range switch in maxi-

mum position, A/V control in minimum position, and Output Selector switch (if present) in either DC position.

3 Weld Cables Connect grid to generator weld

output terminals using proper size weld cables with correct connectors (polarity is not important).

4 Voltmeter 5 Clamp-On Ammeter Connect voltmeter and ammeter as

shown, if not provided on generator. Start engine and run for several

minutes. Set grid switches and then adjust

generator A/V control so load

equals rated generator output (see nameplate).

Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly.

 Check oil level frequently dur-

ing run-in; add oil if needed.

After one hour (minimum), place A/V control in minimum position, then shut down grid to remove load. Run engine several minutes at no load.

 Stop engine and let cool.

6 Engine Exhaust Pipe Repeat procedure if wetstacking is

present.

OM-491 Page 50

S-0684

Page 55

SECTION 11 – AUXILIARY POWER GUIDELINES

11-1. Selecting Equipment

1 Auxiliary Power Receptacles

– Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

11-2. Grounding Generator To Truck Or Trailer Frame

3 4

GND/PE

Be sure equipment has this symbol and/or wording.

aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577

1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding

Terminal 4 Grounding Cable Use #10 AWG or larger insulated

copper wire.

 If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

Electrically bond generator

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

S-0854

OM-491 Page 51

Page 56

11-3. Grounding When Supplying Building Systems

1 2

GND/PE

1 Equipment Grounding

Terminal 2 Grounding Cable Use #10 AWG or larger insulated

copper wire. 3 Ground Device

 Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

Use ground device as stated in electrical codes.

11-4. How Much Power Does Equipment Require?

AMPERES x VOLTS = WATTS

EXAMPLE 1 : If a drill uses 4.5 amperes at 115 volts, calculate its running power

requirement in watts.

4.5 A x 115 V = 520 W

The load applied by the drill is 520 watts.

VOLTS 115 AMPS Hz

4.5 60

ST-800 576-B

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-

sistive load and requires approximately six times more power while starting the motor than when running (see Section 11-8).

3 Rating Data Rating shows volts and amperes,

or watts required to run equipment.

OM-491 Page 52

EXAMPLE 2 : If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.

(200 W + 200 W + 200 W) + 520 W = 1120 W

The total load applied by the three flood lamps and drill is 1120 watts.

S-0623

Page 57

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-491 Page 53

Page 58

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-491 Page 54

Page 59

11-8. Power Required To Start Motor

4 1

VOLTS AMPS

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GHJKLMNP

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

kVA/HP x HP x 1000

VOLTS

EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4

HP motor with a motor start code of M.

Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2

11.2 x 1/4 x 1000 230

= 12.2 A

CODE 60

Starting the motor requires 12.2 amperes.

AC MOTOR

230 2.5

1/4

= STARTING AMPERAGE

Hz PHASE

1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage To find starting amperage:

Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage.

Step 2: Find Motor HP and Volts. Step 3: Determine starting amper-

age (see example). Welding generator amperage out-

put must be at least twice the motor’s running amperage.

S-0624

11-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of

Generator Output

Always start non-resistive (motor) loads in order from largest to smallest, and add resistive loads last.

2 5 Second Rule If motor does not start within 5

seconds, turn off power to prevent motor damage. Motor requires more power than generator can supply.

Ref. ST-800 396-A / S-0625

OM-491 Page 55

Page 60

11-10. Typical Connections To Supply Standby Power

 Customer-supplied equipment is required if

generator is to supply standby power during emergencies or power outages.

120/240 Volt

60 Hz

Three-Wire

Service

Load

240 V

120 V

Neutral

240 V

120 V

1 Power Company Service

Meter

2 Main and Branch Overcurrent

Protection

3 Double-Pole, Double-Throw

Transfer Switch

Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection.

4 Circuit Breakers or Fused

Disconnect Switch Obtain and install correct switch. 5 Extension Cord Select as shown in Section 11-11. 6 Generator Connections Connect terminals or plug of ade-

quate amperage capacity to cord. Follow all applicable codes and

safety practices. Turn off or unplug all equipment

connected to generator before starting or stopping engine. When starting o r s t o p p i n g , t h e e ngine has low speed which causes low voltage and frequency.

7 Load Connections

120/240 Volt

Single-Phase

Three-Wire

Generator Output

Connection

240 V

120 V

Ground

Item 4 is not necessary if circuit protection is already present in welding generator auxiliary power output circuit.

OM-491 Page 56

S-0405-A

Page 61

11-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

Current

(Amperes)

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.

Load (Watts) 4 6 8 10 12 14

Current

(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

Load (Watts) 4 6 8 10 12 14

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

OM-491 Page 57

Page 62

 Hardware is common and

not available unless listed.

SECTION 12 – PARTS LIST

11 12

117

112 (CV)

111 (CV)

113 (CV)

104 (Fig. 12-7)

105

106

102

103(CC)

101(CC)

115 (CV)

116 (CV)

114 (CV)

110–(Fig. 12-4 or 12-5)

OM-491 Page 58

109

108

107

CC CC Models Only CV CC/CV Models Only

Figure 12-1. Main Assembly

100

Page 63

Big Blue 502, 602 Only

120

119

802 265-F

OM-491 Page 59

Page 64

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-1. Main Assembly

1 189 824 PANEL, gen LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 191 626 BUMPER, door engine access 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 190 518 LABEL, diesel engine maintenance Perkins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 191 623 LABEL, warning all panels must be in place while running 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 +189 825 DOOR, engine access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 190 572 STIFFENER, engine access door 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 199 592 LATCH, paddle series 20 (black) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ♦190 126 LATCH, paddle series 20 (stainless steel) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 087 341 BUMPER, door 1.000 OD x .750 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 190 076 CHANNEL, stiffener engine access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 190 992 KEEPER, latch engine access door 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 189 975 HINGE, door access 180deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 189 826 PANEL, rocker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 190 190 TANK, coolant recovery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 Z1 189 395 REACTOR, ac 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 1T 038 621 BLOCK, term 30A 4 pole frict term str 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038 620 LINK, jumper term blk 30A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 260 HARNESS, unit weld control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 166 680 CONNECTOR, (kit) rect univ 084 12P/S 3 row plug cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

187 654 SEAL, wire univ 12P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 141 270 CONNECTOR, (kit) rect univ 084 4P/S 1 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . .

16 081 499 BRACKET, mtg strip terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 188 600 FRAME, mtg reactor and rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 189 708 FIREWALL, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 190 182 PANEL, side air box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 189 763 BRACKET, mtg air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 189 764 AIR CLEANER, intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*192 938 FILTER, air element primary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*♦192 939 FILTER, air element safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 189 618 HOSE, air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 107 816 HOSE, SAE .250 ID x .500 OD xc oil (order by ft) 5ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134 835 HOSE, SAE .312 ID x .560 OD xc oil (order by ft) 4ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 145 282 FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 192 750 BASE, fuel filter w/adapter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 *192 744 FILTER, fuel spin-on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 192 741 BLOCK, spacer mtg filter base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 189 464 SEAL, weather lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 191 460 CLIP, spring lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 CR8 155 309 CONTACTOR, solenoid 12VDC cont 400A inrush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 188 947 FRAME ASSEMBLY, center upright 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 192 362 BRACKET, mtg nyl 1/2 conduit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 +189 154 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 196 220 BRACKET, hold down fuel tank rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 +193 684 COVER, top (Big Blue 402 only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 +189 706 COVER, top, (Big Blue 502, 602 only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 189 052 GROMMET, plastic neck filler fuel (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 190 198 CAP, tank screw-on 3.500 in w/vent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 107 990 LABEL, use diesel fuel only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 108 487 LABEL, warning falling equipment 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 010 875 CLAMP, muffler 2.000 dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 105 734 PIPE, muffler extension elbow 9Big Blue 402 only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 191 176 PLUG, radiator access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 191 354 SUPPORT, cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-491 Page 60

Page 65

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-1. Main Assembly (Continued)

44 189 245 TANK, fuel 23gal (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 124 253 BUSHING, tank fuel 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

084 173 CLAMP, hose .460 – .545clp dia slfttng 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 189 912 FITTING, stl barbed elbow w/.047 in orf zinc pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 189 909 FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 189 913 FITTING, stl barbed elbow zinc pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 190 142 SENDER, fuel gauge 9.7500 deep tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 189 910 FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 189 908 VALVE, drain fuel 180deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 181 572 BUSHING, tank fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 Figure 12-6 GENERATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 013 367 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 193 314 MANIFOLD, exhaust muffler (Big Blue 402 only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 190 238 ENGINE, Perkins dsl elec 3.152 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*192 936 FILTER, oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*192 744 FILTER, fuel spin-on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*192 937 FILTER, fuel secondary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*195 615 SWITCH, coolant temperature 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*195 616 SWITCH, oil pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 *193 163 BELT, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 189 621 HOSE, radiator lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 189 622 HOSE, radiator upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 +200 458 GUARD, belt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147 923 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 197 505 RADIATOR, w/shroud and 7# cap 3 row core 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

605 982 CAP, radiator pressure 7 lb 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 Deleted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 189 717 UPRIGHT, rear Perkins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 190 207 CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 108 081 TERMINAL PROTECTOR, battery post mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 190 206 CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 190 896 BATTERY, stor 12V 650crk 110rsv gp 24 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 168 385 LABEL, warning battery explosion can blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 +189 290 BATTERY BOX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 189 293 HOLD DOWN, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 197 734 GUARD, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147 923 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 +189 828 PANEL, engine side RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 189 827 PANEL, gen RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 199 849 SCREW, 625-11 x 4.00hexhd pln gr 5 pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 071 731 WASHER, flat .656 ID x 2.250 OD x .187T stl pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 189 146 BRACKET ASSEMBLY, mtg RH Perkins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189 150 BRACKET ASSEMBLY, mtg LH Perkins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 071 890 RETAINER, mount eng/gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 071 730 TUBING, stl .875 OD x 12ga wall x 2.500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 083 476 MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 135 205 NUT, 625-11 .94hex .76H stl pld elastic stop nut 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 505 HOSE, oil drain assy 32 in (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 165 271 VALVE, oil drain 3/8-18NPTF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 176 529 FITTING, hose brs barbed fem 1/2tbg x 3/8NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 113 854 HOSE, SAE .500 ID x .780 OD xc oil (order by ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 191 610 FITTING, hose stl elbow .500tbg x 3/4-16 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 190 180 WASHER, flat .750 ID x 1.250 OD x .125T stl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 191 499 LINE, fuel return 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191 608 FITTING, cprsn brs nut 1/4tbg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191 606 FITTING, cprsn brs sleeve 1/4tbg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Item

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Part

No.

Description

Quantity

Figure 12-1. Main Assembly (Continued)

87 191 500 LINE, fuel supply 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191 609 FITTING, flrd stl invt nut 5/16tbg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191 607 FITTING, cprsn brs sleeve 5/16tbg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 CR1, CR2 090 104 RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg 2. . . . . . . . . . . . . . . . . . . . . .

190 252 HARNESS, engine control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 6T 190 210 BLOCK, term 5-3-3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 D8/C8 189 701 DIODE/CAPACITOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91 CB10 190 374 CIRCUIT BREAKER, auto reset 12VDC 40A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG7 168 071 CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 166 680 CONNECTOR, (kit) rect univ 084 12P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . .

187 654 SEAL, wire univ 12P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 190 196 PANEL, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 12-2, Figure 12-3 CONTROL BOX ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 189 731 FIREWALL, lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 173 352 EXTRUSION, rubber clamp/bulb (order by ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96 191 446 EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) 6ft. . . . . . . . . . . . . . . . . . . . . . . . . .

97 190 250 LABEL, warning do not weld on base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98 191 512 BRACKET, hold down fuel tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 191 897 BRACKET, mtg unit 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 190 179 PANEL, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 R4

191 292 RESISTOR, WW fxd 375W 50 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 R3 189 699 RESISTOR, WW tap 375W 10 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 R2

189 699 RESISTOR, WW tap 375W 10 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 Figure 12-7 MAIN RECTIFIER ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105 191 448 TOP, cover front upright 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106 190 058 NUT, .250-20 u-nut multi-thread 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049 525 NUT, 312-18 u-nut multi-thread 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107 +188 946 UPRIGHT, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108 190 010 LABEL, caution do not use ether 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109 134 792 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110 Figure 12-4, Figure 12-5 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111 112 PC1 113 T1 114 115

116 CB6

RC11

193 453 BRACKET, mtg box fcr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189 143 MODULE, field current regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 371 XFMR, 115V pri 24vct 8A w/leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 138 BRACKET, mtg circuit breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 323 BOOT, circuit breaker clear hex nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 185 HARNESS, transformer (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

083 432 CIRCUIT BREAKER, man reset 1P 10A 250VAC frict 1. . . . . . . . . . . . . . . . . . . . . . . . .

167 640 CONNECTOR, (kit) rect univ 084 4p/s 1 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . .

117 191 307 COVER, plate 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

118 176 230 LABEL, warning hot exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

119 189 535 PIPE, exhaust (Big Blue 502, 602 only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 105 740 Muffler, exhaust engine 1.925 inlet/outlet (Big Blue 502,602 only) 1. . . . . . . . . . . . . . . . . . . . . .

190 469 KIT, label (includes safety and informational labels) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 190 469.

*Recommended Spare Parts.

CC models only.

CC/CV models only.

♦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-491 Page 62

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802 278-B

Figure 12-2. Control Box Assembly – CC Models

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-2. Control Box Assembly – CC Models (Figure 12-1 Item 93)

1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 046 432 HOLDER, fuse mintr .250 x 1.250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 189 385 CONTROL BOX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 253 HARNESS, control box, weld control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 C12 191 944 CAPACITOR, polyp met film 10. uf 250 vac 10% 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 CR7 188 636 RELAY, OCV control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 D1/C1 189 701 DIODE/CAPACITOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 SR1, SR2 035 704 RECTIFIER, integ 40A 800V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CR5 090 104 RELAY, encl 12VDC SPST 30A/15VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 2T, 3T 190 210 BLOCK, term 5-3-3 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC5 147 663 CONNECTOR, (kit) rect univ 084 15P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . .

RC3, RC4 166 679 CONNECTOR, (kit) rect univ 084 12P/S 3 row rcpt cable/panel lkg 2. . . . . . . . . . . . . . . .

RC1, 2, 7 168 071 CONNECTOR, (kit) rect univ 084 9P/S 3 row rcpt cable/panel lkg 3. . . . . . . . . . . . . . . .

10 CB11, 12, 13 139 266 CIRCUIT BREAKER, man reset 1P 15A 250VAC frict 3. . . . . . . . . . . . . . . . . . . . .

11 194 483 COVER, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 177 136 CLAMP, capacitor 1.375dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 C9 087 110 CAPACITOR, elctlt 240uf 200VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 R6 141 424 RESIST OR, ww fxd 30 w 25 ohm faston te 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.

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Item

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Figure 12-3. Control Box Assembly – CC/CV Models

Part

No.

Description

802 360

Quantity

Figure 12-3. Control Box Assembly – CC/CV Models (Figure 12-1 Item

93)

1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 046 432 HOLDER, fuse mintr .250 x 1.250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 189 385 CONTROL BOX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 134 201 STAND-OFF, support pc card 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PC9 192 224 CIRCUIT CARD ASSY, display 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 C9 087 110 CAPACITOR, elctlt 240uf 200VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 177 136 CLAMP, capacitor 1.375dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197 745 HARNESS, control box, cv weld control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 SR1 035 704 RECTIFIER, integ 40A 800V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 CR5 090 104 RELAY, encl 12VDC SPST 30A/15VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 2T, 3T 190 210 BLOCK, term 5-3-3 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC5 147 663 CONNECTOR, (kit) rect univ 084 15P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . .

RC3, RC4 166 679 CONNECTOR, (kit) rect univ 084 12P/S 3 row rcpt cable/panel lkg 2. . . . . . . . . . . . . . . .

RC1, 2, 7 168 071 CONNECTOR, (kit) rect univ 084 9P/S 3 row rcpt cable/panel lkg 3. . . . . . . . . . . . . . . .

11 CB11, 12, 13 139 266 CIRCUIT BREAKER, man reset 1P 15A 250VAC frict 3. . . . . . . . . . . . . . . . . . . . .

12 194 483 COVER, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.

OM-491 Page 64

Page 69

 Hardware is common and

not available unless listed.

8 9

Figure 12-4. Panel, Front w/Components – CC Models

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-4. Panel, Front w/Components – CC Models (Figure 12-1 Item

110)

1 191 631 PLATE SCREENED, ident control rating; when ordering this item,. . . . . . . . . . . . . . . . . .

the nameplate should also be ordered) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 NAMEPLATE, screened (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 191 359 PANEL, engine/weld control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S3 189 382 SWITCH, range/changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

802 266-C

Quantity

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-4. Panel, Front w/Components – CC Models (Continued)

RC6 192 558 HARNESS, range (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148 439 HOUSING, rect univ 084 4p/s 1 row rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R1 188 635 RHEOSTAT, WW 300W 34 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 254 HARNESS, front panel weld control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 S6 011 611 SWITCH, tgl DPDT 15A 125VAC on-none-on spd term chr 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

7 S5 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

8 RC13 032 897 RECEPTACLE, twlk grd 2P3W 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177 859 CONNECTOR, body 5 terminal (to engine control switch S1) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG2 168 071 CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . .

187 651 SEAL, wire univ 9P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 191 308 BRACKET, terminal strip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 PC8 189 744 CIRCUIT CARD ASSEMBLY, filter hf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 S1 176 606 SWITCH, ignition 4posn w/o handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 134 201 STAND-OFF, support 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 257 HARNESS, front panel engine control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 MS1 189 698 SWITCH, magnetic manual reset low current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 4T, 5T 190 210 BLOCK, term 5-3-3 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 S2 021 467 SWITCH, tgl SPST 3A 250V off-none-on spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135 275 CONNECTOR, (kit) rect univ 084 15P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

153 501 CONNECTOR, (kit) rect univ 039 6P/S 3 row 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 655 SEAL, wire univ 15P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197 758 HARNESS, auxiliary power (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 CB1,2,3 093 996 CIRCUIT BREAKER, man reset 1P 20A 250VAC frict 3. . . . . . . . . . . . . . . . . . . . . . . . . .

17 GFCI1 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

18 RC1 147 632 RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 190 861 LABEL, warning electric shock and moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 +191 357 PANEL, aux pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 083 030 STUD, brs .250–20 x 1.750 w/hex collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 601 836 NUT, 250–20 .50hex .19h brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 191 340 PANEL, mtg terminal pwr output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 PC4, PC5 189 744 CIRCUIT CARD ASSEMBLY, filter hf 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 735 WASHER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 181 169 SPACER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 186 621 BOOT, generic output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 193 260 COVER, receptacle 2.250 dia lexan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 193 258 COVER, receptacle GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 190 323 BOOT, circuit breaker clear hex nut 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 193 143 BOOT, magnetic shutdown switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 021 385 BOOT, toggle switch lever 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 119 014 LEVER, switch black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 PL1 191 241 LED, red 12V 4 ind lights panel mtg round 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 FUEL 191 242 GAUGE, fuel elec switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 HM 118 058 METER, hour 12-24VDC 2.25dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 189 161 HANDLE, switch range 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 010 647 PIN, spring CS .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 148 723 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 S12 ♦195 825 SWITCH, polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 ♦059 773 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 ♦010 647 PIN, spring cs .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦196 073 LABEL, do not switch while welding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 201 223 LABEL, warning electric shock power still present 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 190 469.

OM-491 Page 66

Page 71

 Hardware is common and

not available unless listed.

36 35

Figure 12-5. Panel, Front w/Components – CC/CV Models

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-5. Panel, Front w/Components – CC/CV Models (Figure 12-1 Item

110)

1 192 895 PLATE SCREENED, ident control ; when ordering this item,. . . . . . . . . . . . . . . . . .

the nameplate should also be ordered) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 NAMEPLATE, screened (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 191 359 PANEL, engine/weld control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S3 189 382 SWITCH, range/changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC6 192 558 HARNESS, range (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148 439 HOUSING, rect univ 084 4p/s 1 row rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R1 193 118 POT, cp flat 1t 2w 1k ohm linear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

802 332-D

Quantity

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Item

No.

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Mkgs.

Part

No.

Description

Figure 12-5. Panel, Front w/Components – CC/CV Models (Continued)

193 159 HARNESS, front panel weld control CV (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 S6 193 234 SWITCH, rotary 6 position gold contacts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 S5 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG S1 177 859 CONNECTOR, body 5 terminal (to engine control switch S1) 1. . . . . . . . . . . . . . . . . . . . . . .

PLG9 193 183 CONNECTOR, rect cinch 18 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 153 501 CONNECTOR, (kit) rect univ 039 6pp/s 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . .

PLG14 165 668 CONNECTOR, (kit) rect metrmate 10 skt 1 row plug/cable lkg 1. . . . . . . . . . . . . . . . . . . . . .

PLG2 168 071 CONNECTOR, (kit) rect univ 084 9p/s 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

187 651 SEAL, wire univ 9P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG11 114 063 CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 PC6 192 995 CIRCUIT CARD ASSY, connector/receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 191 308 BRACKET, terminal strip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 S1 176 606 SWITCH, ignition 4posn w/o handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 257 HARNESS, front panel engine control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 S2 021 467 SWITCH, tgl SPST 3A 250V off-none-on spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 MS1 189 698 SWITCH, magnetic manual reset low current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 4T, 5T 190 210 BLOCK, term 5-3-3 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135 275 CONNECTOR, (kit) rect univ 084 15P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

153 501 CONNECTOR, (kit) rect univ 039 6P/S 3 row 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 655 SEAL, wire univ 15P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197 758 HARNESS, auxiliary power (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CB1,2,3 093 996 CIRCUIT BREAKER, man reset 1P 20A 250VAC frict 3. . . . . . . . . . . . . . . . . . . . . . . . . .

15 GFCI1 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

16 RC1 147 632 RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 190 861 LABEL, warning electric shock and moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 ♦197 399 LABEL, warning 3 ph auxiliary power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 RC5 ♦182 954 RCPT, str 3P4W 50A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 ♦025 248 STAND-OFF, insul .250-20 x 1.2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 ♦604 102 CONNECTOR, clamp cable 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 ♦197 527 GUARD, circuit breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 ♦197 363 TERMINAL, ring tng screw clamp 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 CB7 ♦196 780 CIRCUIT BREAKER, man reset 3p 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 +191 357 PANEL, auxiliary power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 +♦191 358 PANEL, auxiliary power (full kVA option) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 ♦196 781 BOOT, circuit breaker 3 pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 ♦197 508 PLUG, protective 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 ♦077 440 BUSHING, conduit 1 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 083 030 STUD, brs .250–20 x 1.750 w/hex collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 601 836 NUT, 250–20 .50hex .19h brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 ♦197 291 COVER, receptacle w/gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CT2 ♦197 433 TRANSFORMER, current sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 191 340 PANEL, mtg terminal pwr output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 PC4, PC5 189 744 CIRCUIT CARD ASSEMBLY, filter hf 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 735 WASHER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 134 201 STAND-OFF, support 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 181 169 SPACER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 186 621 BOOT, generic output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 193 260 COVER, receptacle 2.250 dia lexan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 193 258 COVER, receptacle GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 190 323 BOOT, circuit breaker clear hex nut 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 193 143 BOOT, magnetic shutdown switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 021 385 BOOT, toggle switch lever 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 119 014 LEVER, switch black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 170 391 CONN, circ ms protective cap size 20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 PL1 191 241 LED, red 12V 4 ind lights panel mtg round 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-491 Page 68

Page 73

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-5. Panel, Front w/Components – CC/CV Models (Continued)

46 FUEL 191 242 GAUGE, fuel elec switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 HM 118 058 METER, hour 12-24VDC 2.25dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 097 922 KNOB, pointer .875 dia x .250 ID w/set screws plstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 189 161 HANDLE, switch range 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 010 647 PIN, spring CS .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 097 924 KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 158 HARNESS, unit weld control – CV (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 136 810 CONNECTOR, (kit) rect univ 084 4p/s 1 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8 193 184 CONNECTOR, rect cinch 30 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG13 148 439 CONNECTOR, (kit) rect univ 039 10p/s 2 row plug cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 166 680 CONNECTOR, (kit) rect univ 084 12p/s 3 row plug cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

088 731 BUSHING, snap-in nyl .375 ID x .500 mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135 873 CLIP, conduit convoluted 1/2 in mtg hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 654 SEAL, wire univ 12p/s 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

024 103 BLANK, snap-in nyl .750 mtg hole blk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 S12 ♦195 825 SWITCH, polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 ♦059 773 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 ♦010 647 PIN, spring cs .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦196 073 LABEL, do not switch while welding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 201 223 LABEL, warning electric shock power still present 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 190 469.

♦Optional

802 267-A

Figure 12-6. Generator

OM-491 Page 69

Page 74

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-6. Generator (Figure 12-1 Item 53)

1 132 053 SCREW, 375-16 x 1.50hexhd pln gr 5pld 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 183 387 WASHER, conical spring .406 ID x .875 OD pltd 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 195 911 ENDBELL, gen (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 143 220 O-RING, 2.859 ID x .139CS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 190 464 STATOR, exciter/aux pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 +191 478 STATOR, weld assembly complete 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6+♦197 334 STATOR, weld assembly complete (full kVA option) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 013 367 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 190 197 GUARD, generator wire mesh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 172 674 SPRING, ext .240 OD x .041 wire x 3.500pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 191 580 COVER, starter hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 191 576 GUARD, starter Perkins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 039 207 BAFFLE, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 198 627 ROTOR, gen (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 024 617 RING, rtng ext 1.375 shaft x .050thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 053 390 BEARING, ball rdl sgl row 1.370 x 2.830 x .6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 195 547 FAN, rotor gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 049 026 SCREW, M10-1.5 x 25hexhd pln 8.8pln 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 083 883 WASHER, lock .042 ID x 0.709 OD 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 194 468 PLATE, flex 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 605 231 SCREW, M10-1.5 x 35hexhd pln 8.8pln 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 194 512 WASHER, flat 1.250 OD x .406 ID x 7 ga thk stal pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 183 387 WASHER, cone .380 ID x .860OD x .109t stl pld 4000lbs 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 198 631 NUT, m10 hex lock nut stl pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 191 579 COVER, starter hole Perkins/Continental 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 172 555 SCREW, M10-1.5 x 50hexhd pln 8.8pld 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 602 159 SCREW, .312-18 X .75hexwhd 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 601 961 SCREW, .312-18 x 2.25hexhd pln gr 5pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 602 211 WASHER, lock .318 ID x 0.586 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 139 341 WASHER, exciter 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 *190 823 BRUSH, contact 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 188 560 CLIP, spring 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 189 142 BRUSHHOLDER ASSEMBLY, gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 602 242 WASHER, flat .375idx0.875odx.083t stl pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 604 534 SCREW, 312–18X1.25 hex hd–pln gr5 pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 259 HARNESS, brush (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 168 071 CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . .

187 651 SEAL, wire univ 9P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 190 469.

*Recommended Spare Parts. ♦Optional

OM-491 Page 70

Page 75

 Hardware is common and

not available unless listed.

802 279

Figure 12-7. Main Rectifier Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-7. Main Rectifier Assembly (Figure 12-1 Item 104)

1 188 137 CONNECTION BOARD, rectifier AC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 188 517 BUS BAR, connection board 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 188 135 ENCLOSURE, rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 134 201 STAND-OFF, support 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PC3 188 610 CIRCUIT CARD ASSEMBLY, protection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 188 136 INSULATOR, heat sink 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 188 493 HEAT SINK, rectifier al 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 D3, D5, D7 037 956 DIODE, rect 275A 300V SP 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 D2, D4, D6 037 957 DIODE, rect 275A 300V RP 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-491 Page 71

Page 76

Notes

OM-491 Page 72

Page 77

Warranty Questions?

Call 1-877-HOBART1 for your local Hobart distributor.

Service

Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hobart is there to help you, every step of the way.

Effective January 1, 2000

(Equipment with a serial number preface of “LA” or newer)

This limited warranty supersedes all previous Hobart warranties and is exclusive with no other

LIMITED WARRANTY – Subject to the terms and conditions below, Hobart Welding Products., Troy, Ohio, warrants to its original ret a i l p urchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart. THIS WARRANTY IS EXPRESSL Y IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Hobart will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Hobart must be notified in writing within thirty (30) days of such defect or failure, at which time Hobart will provide instructions on the warranty claim procedures to be followed.

Hobart shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or e i ghteen months after the equipment is sent to an International distributor.

1. 5 Years Parts – 3 Years Labor

* Original main power rectifiers * Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources * Plasma Arc Cutting Power Sources * Semi-Automatic and Automatic Wire Feeders * Inverter Power Supplies * Intellitig * Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer .)

3. 1 Year — Parts and Labor

* DS-2 Wire Feeder * Motor Driven Guns (w/exception of Spoolmate

185 & Spoolmate 250) * Process Controllers * Positioners and Controllers * Automatic Motion Devices * RFCS Foot Controls * Induction Heating Power Sources * Water Coolant Systems * HF Units * Grids * Maxstar 140 * Spot Welders * Load Banks * Hobart Cyclomatic Equipment * Running Gear/Trailers * Plasma Cutting Torches (except APT & SAF

Models) * Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches * Induction Heating Coils and Blankets

guarantees or warranties expressed or implied.

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches * Remote Controls * Accessory Kits * Replacement Parts (No labor) * Spoolmate 185 & Spoolmate 250 * Canvas Covers

HOBART’s Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear.

2. Items furnished by Hobart, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than Hobart, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Hobart’s option: (1) repair; or (2) replacement; or, where authorized in writing by Hobart in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Hobart service station; or (4) payment of or credit for the purchase price (less reasonable depreciation bas e d u p o n actual use) upon return of the goods at customer’s risk and expense. Hobart’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Hobart authorized service facility as determined by Hobart. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL HOBART BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART IS EXCLUDED AND DISCLAIMED BY HOBART.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

hobart standard 7/00

Page 78

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

Resources Available

Always provide Model Name and Serial/Style Number.

To locate a Distributor, retail or service location:

Call 1-877-Hobart1 or visit our website at www.HobartWelders.com

For technical assistance:

Call 1-800-332-3281

Contact the Delivering Carrier for:

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.

Contact your Distributor for:

Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information

and Parts) Circuit Diagrams Welding Process Handbooks

File a claim for loss or damage during shipment.

Hobart Welding Products

An Ill inoi s Tool Works Company 600 West Main Street Troy, OH 45373 USA

For Technical Assistance:

Call1-800-332-3281 For Literature Or Nearest Dealer: Call 1-877-Hobart1

PRINTED IN USA  2000 Hobart Welding Products. 1/00

Hobart CONTRACTOR 5040P User guide

Specifications and Main Features

Frequently Asked Questions

User Manual