Miller Electric 500D, 600 X User Manual

OM-4428 215 932K

2007−10

Processes

Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A)
Cutting and Gouging

Description

Engine Driven Welding Generator



Big Blue 500D



Big Blue 600 X

(Deutz-Powered)

Visit our website at

www.MillerWelds.com

File: Engine Drive

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001:2000 Quality
System Standard.

parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

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

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 4/05

TABLE OF CONTENTS

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

1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Engine Hazards 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Compressed Air Hazards 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Additional Symbols For Installation, Operation, And Maintenance 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. California Proposition 65 Warnings 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. Principal Safety Standards 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-8. EMF Information 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers existant en relation avec le moteur 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Dangers liés à l’air comprimé 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 9 . . . . . .

2-6. Proposition californienne 65 Avertissements 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Principales normes de sécurité 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Information EMF 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Warning Label Definitions (For Wordless Labels) 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Manufacturer’s Rating Labels 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Symbols And Definitions 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Weld, Power, And Engine Specifications 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Dimensions, Weights, And Operating Angles 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Volt-Ampere Curves For CC Models 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Volt-Ampere Curves For CC/CV Models 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Fuel Consumption 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Duty Cycle And Overheating 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. AC Generator Power Curve 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Optional Three-Phase Generator Curves 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Using Lifting Eye 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Mounting Welding Generator 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Installing Exhaust Pipe 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Installing Optional Ether Cylinder (Deutz F3L912 Engine Only) 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Activating The Dry Charge Battery (If Applicable) 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Connecting The Battery 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Engine Prestart Checks 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Connecting To Weld Output Terminals 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Selecting Weld Cable Sizes* 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 28 . . . . . . . . . . . . . . . . . . . . .

5-12. Connecting To Remote 14 Receptacle RC14 On CC/CV Models 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Front Panel Controls For CC Models (See Section 6-2) 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) 31 . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Remote Amperage Control On CC Models (Optional) 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Weld Control/Arc Condition Information Label 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 35 . . . . . . . . . . . . . . . . . . . . . .

7-3. Process/Contactor Switch On CC/CV Models 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − OPERATING AUXILIARY EQUIPMENT 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. 120 Volt And 240 Volt Receptacles 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) 39 . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Optional Generator Power Receptacles (Standard Models) 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Generator Power Receptacles (Export Models) 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − MAINTENANCE (DEUTZ F4L2011−POWERED UNITS) 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Maintenance Label (Deutz F4L2011-Powered Units) 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Routine Maintenance (Deutz F4L2011-Powered Units) 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Checking Generator Brushes 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Servicing Air Cleaner (Deutz F4L2011-Powered Units) 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units) 46 . . . . . . . . . . . . . . . . . . .

9-6. Adjusting Engine Speed (Deutz F4L2011-Powered Units) 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-7. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units) 48 . . . . . . . . . . . . . . . . . . . . . .

9-8. Overload Protection (Deutz F4L2011-Powered Units) 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − MAINTENANCE (DEUTZ F3L912−POWERED UNITS) 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Maintenance Label (Deutz F3L912-Powered Units) 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Routine Maintenance (Deutz F3L912-Powered Units) 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Checking Generator Brushes 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4. Servicing Air Cleaner (Deutz F3L912-Powered Units) 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) 54 . . . . . . . . . . . . . . . . . . . .

10-6. Adjusting Engine Speed (Deutz F3L912-Powered Units) 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-7. Servicing Optional Ether Starting Aid (Deutz F3L912-Powered Units) 55 . . . . . . . . . . . . . . . . . . . . . . . . . .

10-8. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) 56 . . . . . . . . . . . . . . . . . . . . . . .

10-9. Overload Protection (Deutz F3L912-Powered Units) 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − TROUBLESHOOTING 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. Troubleshooting 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − ELECTRICAL DIAGRAMS 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − RUN-IN PROCEDURE 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-1. Wetstacking 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-2. Run-In Procedure Using Load Bank 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-3. Run-In Procedure Using Resistance Grid 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 14 − GENERATOR POWER GUIDELINES 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 15 − PARTS LIST 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom_2007−04

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

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

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 1-7. 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.

 Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

 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.

 Indicates special instructions.

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

 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.

 Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

 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.

 Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

 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 in inverters after stop­ping engine.

 Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

 Do not touch hot parts bare handed.
 Allow cooling period before working on equip-

ment.

 To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT 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.

OM-4428 Page 1

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 local forced ventilation at the

arc to remove welding fumes and gases.

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

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

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

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

 Do not weld in locations near degreasing, cleaning, or spraying 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 while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

 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).

 Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

 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, sparks, 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.

 After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

 Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

NOISE can damage hearing.

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.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays that

can burn eyes and skin. Sparks fly off from the weld.
 Wear an approved welding helmet fitted with a proper shade of filter

lenses 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,

glare, and sparks; warn others not to watch the arc.

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

rial (leather, heavy cotton, or wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums,

or pipes, can cause them to blow up. Sparks can fly off

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

 Remove all flammables within 35 ft (10.7 m) of the welding arc. If

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

 Do not weld where flying sparks can strike flammable material.
 Protect yourself and others from flying sparks and hot metal.
 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.

Noise from some processes or equipment can dam­age hearing.

 Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect Implanted
Medical Devices.

 Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

 Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
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, physical damage, 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.

 Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

 Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

OM-4428 Page 2

1-3. Engine Hazards

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.

FUEL can cause fire or explosion.

 Stop engine and let it cool off before checking or

adding fuel.

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

any sparks or open flames.

 Do not overfill tank — allow room for fuel to expand.
 Do not spill fuel. If fuel is spilled, clean up before starting engine.
 Dispose of rags in a fireproof container.
 Always keep nozzle in contact with tank when fueling.

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 doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

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

parts.

 Reinstall doors, panels, covers, or guards 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.

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 over-

flow 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.

Using a generator indoors CAN KILL
YOU IN MINUTES.

 Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

 NEVER use inside a home or garage, EVEN IF

doors and windows are open.

 Only use OUTSIDE and far away from windows, doors, and

vents.

BATTERY ACID can BURN SKIN and EYES.

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

ENGINE HEAT can cause fire.

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

surfaces or flammables.

 Keep exhaust and exhaust pipes way from

flammables.

HOT PARTS can cause severe burns.

 Do not touch hot parts bare handed.
 Allow cooling period before working on equip-

ment.

 To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can
cause serious injury or death.

 Do not use compressed air for breathing.
 Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

 Wear approved safety goggles.
 Do not direct air stream toward self or others.

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.

TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.

 Release air pressure from tools and system be-

fore servicing, adding or changing attach­ments, or opening compressor oil drain or oil fill
cap.

OM-4428 Page 3

HOT METAL from air arc cutting and

READ INSTRUCTIONS.

gouging can cause fire or explosion.

 Do not cut or gouge near flammables.
 Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury.

 Do not touch hot compressor or air system

parts.

 Let system cool down before touching or ser-

vicing.

 Read Owner’s Manual before using or servic-

ing unit.

 Stop engine and release air pressure before

servicing.

 Use only genuine replacement parts from the

manufacturer.

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

FIRE OR EXPLOSION hazard.

 Do not install or place unit on, over, or near

combustible surfaces.

 Do not install unit near flammables.

 Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

 Use lifting eye to lift unit and properly installed

accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).

 Lift and support unit only with proper equipment

and correct procedures.

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

extend beyond opposite side of unit.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or

stopping engine.

 Do not let low voltage and frequency caused by

low engine speed damage electric motors.

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

where applicable.

FLYING SPARKS can cause injury.

WELDING WIRE can cause injury.

 Do not press gun trigger until instructed to do

so.

 Do not point gun toward any part of the body,

other people, or any metal when threading
welding wire.

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.

 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.

MOVING PARTS can cause injury.

 Keep away from moving parts.
 Keep away from pinch points such as drive

rolls.

OM-4428 Page 4

READ INSTRUCTIONS.

 Read Owner’s Manual before using or servic-

ing unit.

 Use only genuine replacement parts from the

manufacturer.

 Perform engine and air compressor mainte-

nance and service according to this manual
and the engine/air compressor (if applicable)
manuals.

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

promptly correct any interference problem resulting from the
installation.

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

equipment at once.

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

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

1-6. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)

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.

 Electromagnetic energy can interfere with

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

 Be sure all equipment in the welding area is

electromagnetically compatible.

 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 to this manual.

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

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

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc­tive harm.

For Diesel Engines:

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

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: [phone], website:www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields

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

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

Ontario, Canada L4W 5NS (phone: [phone] or in Toronto
416-747-4044, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036–8002 (phone:
212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (phone: [phone], web­site: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1. Keep cables close together by twisting or taping them, or using a
cable cover.

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 Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

OM-4428 Page 5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_2007−04fre

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

2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.

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

Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris­ques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-7. 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
internes de l’appareil sont également sous tension à ce moment-là.
En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en
contact avec le fil de soudage sont sous tension. Des matériels mal
installés ou mal mis à la terre présentent un danger.

 Ne jamais toucher les pièces électriques sous tension.
 Porter des gants et des vêtements de protection secs ne compor-

tant pas de trous.

 S’isoler de la pièce et de la terre au moyen de tapis ou d’autres

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

 Ne pas se servir de source électrique à courant électrique dans les

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

 Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

 Si l’utilisation d’une source électrique à courant électrique s’avère

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

 Des précautions de sécurité supplémentaires sont requises dans

des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures mé­talliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder

OM-4428 Page 6

 Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas tra­vailler seul!

 Couper l’alimentation ou arrêter le moteur avant de procéder à

l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR

1910.147 (voir normes de sécurité).

 Installer et mettre à la terre correctement cet appareil conformé-

ment 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 conduc-

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

 Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques chau­des.

 Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est

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

 Mettre l’appareil hors tension quand on ne l’utilise pas.
 Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante 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.

 Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou­blée.

 N’utiliser qu’un matériel en bon état. Réparer ou remplacer

sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.

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

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

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

contact avec tout objet métallique.

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.

DES PIÈCES CHAUDES peuvent

-

e

­r

e

s

u

e

n

o
e

e

e

u
n

e

f

e

c

e

provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

 Ne pas toucher aux pièces chaudes, utiliser les outils recomman

dés et porter des gants de soudage et des vêtements épais pou
éviter les brûlures.

DES PIECES DE METAL ou DES SA­LETES peuvent provoquer des bles­sures dans 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 risquent de projeter du laitier.

 Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES FUMÉES ET LES GAZ peuvent êtr
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’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

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

 Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

 Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.

 Travailler dans un espace fermé seulement s’il est bien ventilé ou

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

 Ne pas souder dans des endroits situés à proximité d’opérations

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

 Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revête­ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et 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.

LES ACCUMULATIONS DE GAZ ri
quent de provoquer des blessures o
même la mort.

 Fermer l’alimentation du gaz protecteur en cas d

non utilisation.

 Veiller toujours à bien aérer les espaces confinés ou se servir d’u

respirateur d’adduction d’air homologué.

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

Le rayonnement de l’arc du procédé de soudag

génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant l
soudage.

 Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

 Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

 Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.

 Porter des vêtements confectionnés avec des matières résistan-

tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.

LE SOUDAGE peut provoquer un in
cendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites pe

provoquer leur éclatement. Des étincelles peuve
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliques peut provoquer des étincelles, une explosion, un surchau
fement ou un incendie. Avant de commencer le soudage, vérifier
s’assurer que l’endroit ne présente pas de danger.

 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.

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

sur des substances inflammables.

 Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

 Des étincelles et des matériaux chauds du soudage peuvent

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

 Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

 Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

 Ne pas effectuer le soudage sur des conteneurs fermés tels que

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

 Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-

peurs inflammables (vapeur d’essence, par exemple).

 Brancher le câble de masse 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, d’étincelles et d’incendie.

 Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

 En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

 Porter des vêtements de protection dépourvus d’huile tels que des

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

 Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

 Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-

ce d’étincelles incandescentes ni de flammes.

 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.

LE BRUIT peut affecter l’ouïe.

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

 Porter des protections approuvés pour les or

les si le niveau sonore est trop élevé.

OM-4428 Page 7

LES CHAMPS MAGNETIQUES peuv-

a

a

a
n

e

s
s

o

e

s

e

t

o

,

-

e

­r

 Placer les bouteilles debout en les fixant dans un support station-

ent affecter des implants médicaux.

 Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

 Les porteurs d’implants doivent d’abord consulter leur médecin

avant de s’approcher des opérations de soudage à l’arc, de sou­dage par points, de gougeage, du coupage plasma ou de chauf­fage par induction.

 Tenir les bouteilles éloignées des circuits de soudage ou autres

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

 Ne jamais souder une bouteille pressurisée − risque d’explosion.
 Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

Si des BOUTEILLES sont endomm
gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du g

sous haute pression. Si une bouteille est endomm
gée, elle peut exploser. Du fait que les bouteilles de gaz fo
normalement partie du procédé de soudage, les manipuler av
précaution.

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

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

 Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la

 Maintenir le chapeau de protection sur la soupape, sauf en cas

 Utiliser les équipements corrects, les bonnes procédures et suffi-

 Lire et suivre les instructions sur les bouteilles de gaz comprimé,

2-3. Dangers existant en relation avec le moteur

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

circuits électriques.

une bouteille.

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

bouteille.

d’utilisation ou de branchement de la bouteille.

samment de personnes pour soulever et déplacer les bouteilles.

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.

L’EXPLOSION DE LA BATTERIE peu
RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gant

en caoutchouc et vêtements de protection lor
d’une intervention sur la batterie.

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

de batterie.

 Eviter de provoquer des étincelles avec les outils en travaillant sur

la batterie.

 Ne pas utiliser le poste de soudage pour charger les batteries ou

des véhicules de démarrage rapide.

 Observer la polarité correcte (+ et −) sur les batteries.

 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en

dernier lieu.

LE CARBURANT MOTEUR peut prov
quer un incendie ou une explosion.

 Arrêter le moteur avant de vérifier le niveau d

carburant ou de faire le plein.

 Ne pas faire le plein en fumant ou proche d’une source d’étincelle

ou d’une flamme nue.

 Ne pas faire le plein de carburant à ras bord; prévoir de l’espac

pour son expansion.

 Faire attention de ne pas renverser de carburant. Nettoyer tou

carburant renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.
 Toujours garder le pistolet en contact avec le réservoir lors du

remplissage.

DES ORGANES MOBILES peuvent pr
voquer des blessures.

 Ne pas approcher les mains des ventilateurs

courroies et autres pièces en mouvement.

 Maintenir fermés et fixement en place les portes, panneaux, re-

couvrements et dispositifs de protection.

 Arrêter le moteur avant d’installer ou brancher l’appareil.

OM-4428 Page 8

 Seules des personnes qualifiées sont autorisées à enlever les por-

tes, panneaux, recouvrements ou dispositifs de protection pour
effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.

 Pour empêcher tout démarrage accidentel pendant les travaux

d’entretien, débrancher le câble négatif (−) de batterie de la borne.

 Ne pas approcher les mains, cheveux, vêtements lâches et outils

des organes mobiles.

 Remettre en place les panneaux ou les dispositifs 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 interven-

tion sur le générateur.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

 Ne pas toucher aux pièces chaudes, utiliser les outils recomman

dés et porter des gants de soudage et des vêtements épais pou
éviter les brûlures.

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

 Il est préférable de vérifier le liquide de refroi-

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

 Toujours vérifier le niveau de liquide de refroidissement dans le

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

 Si le moteur est chaud et que le liquide doit être vérifié, opérer com-

me suivant.

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

le bouchon du radiateur.

 Dévisser le bouchon légèrement et laisser la vapeur s’échapper

avant d’enlever le bouchon.

L’utilisation d’un groupe autonome

t
,

e

-

e

s

r

u

à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.

 Les fumées d’un groupe autonome contient du

monoxyde de carbone. C’est un poison invisi­ble et inodore.

 JAMAIS utiliser dans une maison ou garage,

même avec les portes et fenêtres ouvertes.

 Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et

bouches aération.

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.

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

 Ne pas renverser la batterie.
 Remplacer une batterie endommagée.

 Rincer immédiatement les yeux et la peau à l’eau.

2-4. Dangers liés à l’air comprimé

RESPIRER L’AIR COMPRIMÉ peut pro­voquer des blessures graves ou causer
la mort.

 Ne pas utiliser l’air comprimé pour respirer.
 Utiliser l’air comprimé seulement pour le cou-

page, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer
des blessures.

 Porter des lunettes de sécurité approuvées.
 Ne pas diriger le jet d’air vers d’autres ou

soi-même.

L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provo­quer des blessures.

 Relâcher la pression d’air de l’outillage ou du

système avant d’effectuer la maintenance,
avant de changer ou de rajouter des éléments
ou avant d’ouvrir la purge ou le bouchon de
remplissage d’huile.

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.

Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un in­cendie ou une explosion.

 Ne pas couper ou gouger à proximité de pro-

duits inflammables.

 Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provo­quer des brûlures et blessures.

 Ne pas toucher le compresseur ou d’autres

éléments du circuit air comprimé chauds.

 Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la

maintenance.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 Arrêter le moteur et relâcher la pression avant

d’effectuer la maintenance.

 N’utiliser que les pièces de rechange recommandées par le

constructeur.

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

Risque D’INCENDIE OU D’EXPLO­SION.

 Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

 Ne pas installer l’appareil à proximité de pro-

duits inflammables.

 Ne pas surcharger l’installation électrique − s’assurer que l’ali-

mentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.

 En utilisant des fourches de levage pour déplacer l’unité, s’assure

que les fourches sont suffisamment longues pour dépasser d
côté opposé de l’appareil.

LA CHUTE DE L’APPAREIL peut blesser.

 Utiliser l’anneau de levage pour lever l’appareil e

les accessoires correctement installées seuls
PAS les bouteilles de gaz. Ne pas dépasser l
poids nominal maximal de l’œilleton (voir les spé
cifications).

 Ne lever et ne soutenir l’appareil qu’avec d

l’équipement approprié et en suivant le
procédures adéquates.

OM-4428 Page 9

LE SURCHAUFFEMENT peut endom-

e

-

-

,

t

a

-

n

u

-

mager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant d

démarrer ou d’arrêter le moteur.

 Ne pas laisser tourner le moteur trop lentement sous risque d’en

dommager le moteur électrique à cause d’une tension et d’une fré
quence trop faibles.

 Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz

s’il y a lieu.

LES ÉTINCELLES VOLANTES ris­quent de provoquer des blessures.

 Porter un écran facial pour protéger le visage e

les yeux.

 Affûter l’électrode au tungstène uniquement à l

meuleuse dotée de protecteurs. Cette manœuv
re est à exécuter dans un endroit sûr lorsque l’o
porte l’équipement homologué de protection d
visage, des mains et du corps.

 Les étincelles risquent de causer un incendie − éloigner toute sub

stance inflammable.

DES ORGANES MOBILES peuvent
provoquer des blessures.

 Ne pas s’approcher des organes mobiles.
 Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

 Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

 Ne pas diriger le pistolet vers soi, d’autres per-

sonnes ou toute pièce mécanique en enga­geant le fil de soudage.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter le fac-

teur 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 remor-

que comme indiqué dans le manuel s’y rappor­tant.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

 Effectuer la maintenance et le service du moteur et du compres-

seur d’air suivant les instructions dans ce manuel ou le manuel
du moteur/compresseur (si applicable).

LE RAYONNEMENT HAUTE FRÉ­QUENCE (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 électri-

cien qualifié les interférences résultant de l’installation.

 Si le FCC signale des interférences, arrêter immédiatement l’ap-

pareil.

 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 un blindage pour réduire les
interférences éventuelles.

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

 L’énergie électromagnétique risque de provo-

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

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

compatible électromagnétiquement.

 Pour réduire la possibilité d’interférence, maintenir les câbles de

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

 Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

 Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

 En cas d’interférences après avoir pris les mesures précéden-

tes, il incombe à l’utilisateur de prendre des mesures supplé­mentaires telles que le déplacement du poste, l’utilisation de câ­bles blindés, l’utilisation de filtres de ligne ou la pose de protec­teurs dans la zone de travail.

OM-4428 Page 10

2-6. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal­formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)

Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi­ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipu­lation.

2-7. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1 de Global Engineering Documents (téléphone :
1-877-413-5184, site Internet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protec­tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan­tilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, 5060 Mississauga, Ontario, Canada

Pour les moteurs à essence :

Les gaz d’échappement des moteurs contiennent des pro­duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.

Pour les moteurs diesel :

Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com­me provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.

L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
Internet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, de American National Standards Institute,

11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900, site Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superin­tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).

2-8. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.

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

Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :

1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.

2. Disposer les câbles d’un côté et à distance 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. Connecter la pince sur la pièce aussi près que possible de la
soudure.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc­tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

OM-4428 Page 11

SECTION 3 − DEFINITIONS

3-1. Warning Label Definitions (For Wordless Labels)

1

2

3

4

5

0 − 50 h Std.

50 h Std.

+

DIESEL

200A

S-177 571

+

0 − 200A

1 Remove unit from shipping

crate. Remove Owner’s
Manual from unit. Follow
instructions to install muffler.

2 Read Owner’s Manual. Read

labels on unit.

3 Use Diesel Fuel only, and fill

fuel tank. Leave room for
expansion.

4 Warning! Watch Out! There

are possible hazards as
shown by the symbols. Read
Owner’s Manual. Follow
instructions to activate
battery.

5 Check oil level. Add oil if

necessary.

6 During the first 50 hours of

operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.

7 After the first 50 hours of

operation, change the oil and
oil filter.

Notes

API CD-MIL L 2104D,

CD/SE, CD/SF

3/96

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)

18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

OM-4428 Page 12

3/8 in (.375 in)

3-2. Manufacturer’s Rating Labels

CC Models CC/CV Models

OM-4428 Page 13

3-3. Symbols And Definitions

A

 Some symbols are found only on CE products.

Stop Engine

Starting Aid Battery (Engine)

Check Injectors/

Pump

Positive Negative

Amperes

Fast (Run, Weld/

Power)

Check Valve

Clearance

Volts Panel/Local Remote

V

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)

3

X

n

Time

h

Three Phase

Electrode

Connection

Duty Cycle

Rated Idle

1

Speed n

Contactor On

U

0

0

Hours

Read Operator’s

Manual

Work Connection

Rated No Load

Voltage (Average)

Rated No Load

Speed

s

G

3

U

I

2

Seconds

Circuit Protector

Engine-Driven,

Three-Phase

Alternator With

Rectifier

Conventional
Load Voltage

Current

1

Hz

n

I

2

Single Phase

Do Not Switch
While Welding

Hertz

Rated Load

Speed

Rated Welding

Current

OM-4428 Page 14

SECTION 4 − SPECIFICATIONS

500 A, 40 Volts DC

Option:

Cylinder, 46.3 HP
(

)

be damaged or unit could tip

! Do not move or operate unit where it could

A

B

C

H

30°

F

802 161 A

4-1. Weld, Power, And Engine Specifications

Welding

Mode

CC/DC

CV/DC

(CC/CV

Models

Only)

Weld

Output

Range

65 − 600 A

(CC Models)

20 − 600 A

(CC/CV
Models)

14 − 40 V

Rated Welding

Output

600 A, 30 Volts DC,

40% Duty Cycle

IFC Rating

500 A, 40 Volts DC,

100% Duty Cycle

550 A, 40 volts DC,

60% Duty Cycle

Maximum

Open-Circuit

Voltage

,

95

56

Generator Power

4 kVA/kW, 34/17 A,

120/240 V AC, 50/60 Hz

Three-Phase Generator

Single-Phase/Three-Phase,

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

120/240 VAC, 60 Hz

*In Addition To Standard

4 kVA/kW Generator Power

4-2. Dimensions, Weights, And Operating Angles

Dimensions

Height

Width

Depth 65-1/8 in (1654 mm)

A 65-1/8 in (1654 mm)
B* 56 in (1422 mm)
C* 46-1/2 in (1181)
D* 9-5/8 in (244 mm)

E 27-1/2 in (699 mm)

F 1 in (25 mm)

G 29-13/16 in (757 mm)

H

* With mounting brackets in center

position. Dimensions vary with
location of mounting brackets.

w/ Deutz
F4L2011

w/ Deutz

F3L912

Lifting Eye Weight Rating:

2500 lb (1134 kg) Maximum

50 in (1270 mm)

(to top of muffler)

28-1/2 in (724 mm)

(mtg. brackets turned in)

30-3/4 in (781 mm)

(mtg. brackets turned out)

9/16 in (14 mm) Dia.

4 Holes

Weight

No fuel: 1690 lb (767 kg)

w/fuel: 1880 lb (853 kg)

No fuel: 1785 lb (810 kg)

w/fuel: 1975 lb (896 kg)

G

B

C

D

Front Panel End

E

Rating

Standard:

Single-Phase,

Option:*

802 161-A

Engine

DEUTZ

Deutz F4L2011

Air/Oil-Cooled, Four

Cylinder, 46.3 HP

Diesel Engine

or

Deutz F3L912,
Air-Cooled, Three
Cylinder, 41.5 HP

Diesel Engine

Fuel

Capacity

25 gal

95 L

! Do not exceed tilt angles or engine could

.

! Do not move or operate unit where it could

tip.

°

20°
20°

30°

803 602

OM-4428 Page 15

4-3. Volt-Ampere Curves For CC Models

100

80

60

40

DC VOLTS

20

0

0 100 200 300 400 500 600 700 800 900

DC AMPERES

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

Ranges
300−Max

185−425
125−320
85−190
55−90

Notes

203 412

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4428 Page 16

4-4. Volt-Ampere Curves For CC/CV Models

A. Stick Mode

100

80

60

40

DC VOLTS

20

0

0 100 200 300 400 500 600 700 800 900

DC AMPERES

B. MIG Mode

100

80

Ranges

275−Max
150−525

110−390
80−240

50−125

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

1000

60

MAX

40

DC VOLTS

20

MIN

0

0 100 200 300 400 500 600 700 800 900 1000

DC AMPERES

C. TIG Mode

100

80

60

40

DC VOLTS

Ranges

50−440
35−320
25−215
15−115

20

0

0 100 200 300 400 500

DC AMPERES

217 811 / 203 415 / 217 810

OM-4428 Page 17

4-5. Fuel Consumption

0

0 50 100 150 200 250 300 350 400 450 500

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

1800 RPM

IDLE

DC WELD AMPERES AT 100% DUTY CYCLE

Notes

193 093

OM-4428 Page 18

4-6. Duty Cycle And Overheating

100% Duty Cycle At 500 Amperes

Continuous Welding

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

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

4-7. AC Generator Power Curve

300

150

250

125

200

100

150

75

AC VOLTS

100

50

50

25

0

0

0 5 10 15 20 25 30

AC AMPERES IN 240V MODE

202 356

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

0102030405060

AC AMPERES IN 120V MODE

193 018

OM-4428 Page 19

4-8. Optional Three-Phase Generator Curves

A. 12 kVA/kW Single-Phase AC Output (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

0

20 40 60 80 100

AC AMPERES

AC VOLTS

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

B. 20 kVA/kW Three-Phase AC Output (No Weld Load)

280

260

240

220

200

180

0 10203040506070

AC AMPERES

OM-4428 Page 20

197 472 / 197 473

SECTION 5 − INSTALLATION

5

-1. Installing Welding Generator

! Always securely fasten weld-

ing generator onto transport

Movement

OR OR

Location/Airflow Clearance

18 in

(460 mm)

18 in

(460 mm)

OR

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

OR

vehicle or trailer and comply
with all DOT and other applica­ble codes.

! Always ground generator

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

! If unit does not have GFCI re-

ceptacles, use GFCI-protected
extension cord.

NOTICE − Do not install unit where
air flow is restricted or engine may
overheat.

 See Section 4-2 for lifting eye rat-

ing.

 See Section 5-3 for mounting in-

formation.

Grounding:

1 Equipment Grounding Terminal

(On Front Panel)
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment

ground terminal to metal vehicle
frame. Use #10 AWG or larger insu­lated copper wire.

 Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

! Bed liners, shipping skids,

and some running gears insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equipment

grounding terminal to bare

metal on the vehicle frame as

shown.

Grounding

GND/PE

1

2

3

install3 2007−04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

OM-4428 Page 21

5-2. Using Lifting Eye

1 Lifting Eye
2 Nut

1

2

3

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 3/8-16 x 1-1/2 in
carriage bolt through slot in bracket
and secure with nut (bolt and nut not
supplied).

Tools Needed:

Notes

Ref. 802 311

Work like a Pro!

OM-4428 Page 22

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

5-3. Mounting Welding Generator

Supporting The Unit

Using Mounting Brackets

! 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.

NOTICE − Do not mount unit by
supporting the base only
mounting brackets. Use cross-

2

OR

1

1

supports to adequately support unit
and prevent damage to base.

Mounting Surface:

1 Cross-Supports
2 Mounting Brackets (Supplied)
Mount unit on flat surface or use

cross-supports to support base.
Secure unit with mounting brack­ets.

3 1/2 in Bolt And Washer

(Minimum − Not Supplied)

4 3/8-16 x 1 in Screws

(Supplied)

To Bolt Unit In Place:

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

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

To Weld Unit In Place:

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

at the four

Tools Needed:

9/16 in

2

Welding Unit In Place

Bolting Unit In Place

2

4

3

install3 2007−04 803 274 / 200 864-A /803 602-B

OM-4428 Page 23

5-4. Installing Exhaust Pipe

Tools Needed:

1/2 in

! Stop engine and let cool.

 Point exhaust pipe in desired di-

rection but always away from front
panel and direction of travel.

Ref. 803 604 / Ref. 215 664

5-5. Installing Optional Ether Cylinder (Deutz F3L912 Engine Only)

! Stop engine.
! Improper handling or expo-

1

2

3

4

5

6

! Do not use Ether Starting Aid

Remove rubber access plug from
cover.

1 Ether Cylinder
2 Nozzle
Remove cover and clean cylinder

nozzle.
3 Clamp
4 Fitting
5 Cap
6 Valve
Remove cap and clean fitting.

Install cylinder on fitting. Tighten
clamp.

 After installing cylinder, wait at

Put cap on fitting when cylinder is
removed.

Reinstall plug in cover.

sure to ether can harm your
health. Follow manufactur­er’s safety instructions on
cylinder.

while engine is running.

least 10 minutes before using
to let ether particles settle and
prevent atomizer plugging.

ether1 7/96 − 153 382-A / Ref. 215 664

OM-4428 Page 24

5-6. Activating The Dry Charge Battery (If Applicable)

3

2

1

4

! Always wear a face shield,

rubber gloves and protective
clothing when working on a
battery.

Remove battery from unit.
1 Vent Caps
2 Sulfuric Acid Electrolyte

(1.265 Specific Gravity)
3 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.

4 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

Tools Needed:

30 A For 12 Minutes

5-7. Connecting The Battery

! Connect negative (−) cable last.

−

OR

+

−

drybatt1 6/05 − S-0886

 Reinstall cover after connecting battery.

+

Tools Needed:

1/2 in

Ref. 215 664 / 803 605 / S-0756-C

OM-4428 Page 25

5-8. Engine Prestart Checks

Full

Diesel

Deutz F4L2011 Engine

Full

Full

Diesel

Deutz F3L912 Engine

 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
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 13.

Fuel

NOTICE − Do not use gasoline. Gasoline
will damage engine.

Add fresh diesel fuel before starting to pre­vent air from entering the fuel system (see
engine maintenance label for fuel specifica­tions). Leave filler neck empty to allow room
for expansion.

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

Full

Ref. 803 657 / 803 658

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).

 To improve cold weather starting:

Use optional Starting Aid switch (see
Section 6-1 or 7-1).

Keep battery in good condition. Store
battery in warm area.

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

Use correct grade oil for cold weather
(see Section 9-1 or 10-1).

OM-4428 Page 26

5-9. Connecting To Weld Output Terminals

! Stop engine.

1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal

! Failure to properly connect weld

cables may cause excessive heat and
start a fire, or damage your machine.

3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output termi-

nal. Slide weld cable terminal onto weld output
terminal and secure with nut so that weld cable
terminal is tight against copper bar. Do not

place anything between weld cable termi­nal and copper bar. Make sure that the sur­faces of the weld cable terminal and cop­per bar are clean.

Stick and TIG Welding

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

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

If equipped with optional Polarity switch or op­tional Polarity/AC switch, connect electrode
holder cable to Electrode (+) terminal on left
and work cable to Work (−) terminal on right.

MIG and FCAW Welding

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 7-3).

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

If equipped with optional Polarity switch or op­tional Polarity/AC switch, connect wire feeder
cable to Electrode (+) terminal on left and
work cable to Work (−) terminal on right.

Tools Needed:

3/4 in

6

3

4

5

Correct Installation

1

Do not place

anything between

weld cable terminal

and copper bar.

2

Incorrect Installation

803 602 / 803 778-A

OM-4428 Page 27

5-10. Selecting Weld Cable Sizes*

100 ft (30 m) or Less

Weld Output

Terminals

! Stop engine before

connecting to weld
output terminals.

! Do not use worn, dam-

aged, undersized, or
poorly spliced cables.

Welding

Amperes

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

10 − 60%

Duty

Cycle

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

60 − 100%

Duty

10 − 100% Duty Cycle

Cycle

400 ft

(120 m)

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

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

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

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

500 2/0 (70) 3/0 (95) 4/0 (120)

*Chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-F

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

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

5-11. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models

1 Remote Amperage Adjust

Receptacle RC13
Connect optional remote control to

1

RC13 (see Section 6-3).

OM-4428 Page 28

Ref. 154 862-A / 048 720-K / 803 602

5-12. Connecting To Remote 14 Receptacle RC14 On CC/CV Models

24 VOLTS AC

OUTPU

distance remote

OUTPUT

Socket* Socket Information

A 24 volts ac. Protected by sup-

24 VOLTS AC

B Contact closure to A completes

C Output to remote control:+10

plementary protector CB5.

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.

OR

Ref. 803 602

REMOTE

D Remote control circuit common.

T

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 supplementary

I

protector CB6.

Contact closure to I completes
115 volt ac contactor control

J

circuit.

K Chassis common.

volt ac circuit.

Notes

Start Your Professional

Welding Career Now!

400 Trade Square East, Troy, Ohio 45373

1-800-332-9448 www.welding.org

Over 80,000 trained

since 1930!

OM-4428 Page 29

SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS

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

81314976

3

4

5

OM-4428 Page 30

12

10

11

1

2

215 663 / 803 602

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

Engine Starting Controls

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

weather starting (see starting instructions fol­lowing).

2 Engine Control Switch
Use switch to start and stop engine.
To Start:

NOTICE − Do not use ether. Using ether
voids warranty.

 If engine does not start, let engine come

to a complete stop before attempting re­start.

Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.

Below 325 F (05 C): push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.

To Stop: turn Engine Control switch to Off
position.

Engine Gauges And Meters

3 Engine Hour Meter
Use hour meter to monitor engine run time to

help schedule maintenance.
4 Fuel Gauge
Use gauge to check fuel level.
To check fuel level when engine is not run-

ning, turn Engine Control switch to Run posi­tion.

5 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 en-

gine is running, and about 12 volts dc when
the engine is stopped.

6 Engine Coolant Temperature Gauge
Normal temperature is 180 - 203° F (82 - 95°

C). Engine stops if temperature exceeds 220°
F (104° C).

7 Engine Oil Pressure Gauge
Normal pressure is 30 − 60 psi (207 − 414

kPa). 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 output control 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 10).

8 Ampere Range Switch

NOTICE − 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.

9 Amperage Adjust Control
Control adjusts amperage within range se-

lected by Ampere Range switch. Weld output
would be about 180 A DC with controls set as
shown (50% of 150 to 330 A).

 The numbers around the control are for

reference only and do not represent an
actual percentage value.

10 Stick/TIG Selection Switch
Use switch to disable the max OCV circuit

and the arc drive (dig) circuit for scratch start
TIG welding (see max OCV note under Weld
Controls).

When switch is in the Stick position, the max
OCV circuit resets Amperage Adjust Control
R1 to maximum when the arc breaks.

Also in the Stick position, the arc drive (dig)
circuit provides additional amperage during
low voltage (short arc length conditions) to
prevent “sticking” electrodes.

When switch is in Scratch Start TIG position,
the max OCV and arc drive (dig) circuits are
disabled and OCV changes when the control
is adjusted.

11 Amperage Adjust Switch And Remote

Amperage Adjust Receptacle

Connect optional remote control to RC13
(See Section 5-11). 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 5-11 and 6-3).

12 Polarity Switch (Optional)

NOTICE − Do not switch under load.

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

Weld Meters

13 AC/DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output

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

14 AC/DC Ammeter (Optional)
Ammeter displays amperage output of the

unit.

OM-4428 Page 31

6-3. Remote Amperage Control On CC Models (Optional)

1

1 Remote Amperage Adjust

Receptacle RC13
Connect optional remote control to

RC13 (see Section 5-11).

Example: Combination Remote Amperage Control (Stick)

6-4. Weld Control/Arc Condition Information Label

In Example:

Range = 115 to 330 A DC

Percentage Of Range = 50%

Max = About 240 A DC (50% of 150 to 330)

Max (240 A DC)

Min (84 A DC)

Adjust Optional Remote ControlSet Switches Set Range Set Control

Ref. 154 862-A / Ref. 215 663 / 803 602

 Set weld controls as shown to

achieve softer or stiffer arc condi­tions for different applications.

OM-4428 Page 32

212 944-A

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4428 Page 33

SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS

7-1. Front Panel Controls For CC/CV Models (See Section 7-2)

9141510 76

3

4

5

2

OM-4428 Page 34

13

OR

8

12

11

1

215 664 / 802 602

7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)

Engine Starting Controls

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

weather starting (see starting instructions fol­lowing).

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

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

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

To Start:

NOTICE − Do not use ether. Using ether
voids warranty.

 If engine does not start, let engine come

to a complete stop before attempting re­start.

Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.

Below 325 F (05 C): push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.

To Stop: turn Engine Control switch to Off
position.

Engine Gauges And Meters

3 Engine Hour Meter
Use hour meter to monitor engine run time to

help schedule maintenance.
4 Fuel Gauge
Use gauge to check fuel level.
To check fuel level when engine is not run-

ning, turn Engine Control switch to Run posi­tion

5 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.

6 Engine Coolant Temperature Gauge
Normal temperature is 180 - 203° F (82 - 95°

C). Engine stops if temperature exceeds 220°
F (104° C).

7 Engine Oil Pressure Gauge
Normal pressure is 30 − 60 psi (207 − 414

kPa). Engine stops if pressure is below 10 psi
(69 kPa).

Weld Controls

8 Process/Contactor Switch
See Section 7-3 for Process/Contactor

switch information.
9 Ampere Range Switch

NOTICE − Do not switch under load.

Use switch to select weld amperage range.
Use the lowest four ranges for Stick and TIG

welding. Read the upper set of numbers at
each range for Stick welding and the lower set
at each range for TIG welding.

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.

10 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 in TIG mode, but has no effect in Stick
and MIG modes.

Weld output would be about 250 A DC with
controls set as shown (50% of 110 to 390 A).

 The numbers around the control are for

reference only and do not represent an
actual percentage value.

11 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 5-12 and 7-4).

12 Polarity Switch (Optional)

NOTICE − Do not switch under load.

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

13 Polarity/AC Switch (Optional)

! Electric shock can kill.
! 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.

NOTICE − Do not switch under load.

Use Polarity/AC switch to select AC or DC
weld output and DC weld output polarity. For
Direct Current Electrode Negative (DCEN),
turn switch to − (Negative) position. For Direct
Current Electrode Positive (DCEP), turn
switch to + (Positive) position. For weld pro­cesses that require alternating current (AC),
use AC position.

Weld Meters

14 AC/DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output

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

15 AC/DC Ammeter (Optional)
Ammeter displays amperage output of the

unit.

OM-4428 Page 35

7-3. Process/Contactor Switch On CC/CV Models

1 Process/Contactor Switch

! Weld output terminals are ener-

gized when Process/Contactor
switch is in an Weld Terminals

1

Always On position and the en­gine is running.

! DC voltage is still present at the

weld terminals when Process/
Contactor switch is in the Re­mote On/Off Switch Required −
Stick position and the engine is
running.

Use switch to select weld process and
weld output on/off control (see table be­low and Section 7-4).

Place switch in Remote On/Off Switch
Required positions to turn weld output
on and off with a device connected to
the remote 14 receptacle.

Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.

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

When switch is in a Stick position, the
arc drive (dig) circuit provides addition­al amperage during low voltage (short
arc length conditions) to prevent “stick­ing” electrodes.

The arc drive (dig) circuit is disabled
when switch is in MIG or TIG positions.

 Place switch in Weld Terminals Al-

ways On - Stick position when us­ing optional three-phase generator
(see Section 8-2).

 The engine auto idle option does

not work in the Remote On/Off
Switch Required-TIG mode.

Process/Contactor Switch Settings

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

Remote On/Off Switch Re-

quired − TIG, HF Required

Or Scratch Start TIG

Remote On/Off Switch

Required − Stick

Remote On/Off Switch
Required − CV Feeder

Using Remote

Weld Terminals Always On −

Wire

Weld Terminals Always On −

Stick

Weld Terminals Always On −

TIG, Scratch Start

OM-4428 Page 36

GTAW With HF Unit, Pulsing

Device, Or Remote Control

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

MIG (GMAW) At Remote 14 Receptacle Active

MIG (GMAW) Electrode Hot Active

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting

And Gouging

TIG Scratch Start (GTAW) Electrode Hot Active

At Remote 14 Receptacle Not Active

Electrode Hot Active

7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)

1 Remote 14 Receptacle RC14
Connect optional remote control to

RC14 (see Section 5-12).

1

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 = 110 to 390 A DC

Min = 110 A DC

Max = 390 A DC

Max (390 A DC)

Min (110 A DC)

Adjust Optional Remote Control

In Example:

Process = TIG (Using Remote On/Off)

Range = 35 to 320 A DC

Percentage Of Range = 50%

Min = 35 A DC

Max = About 178 A DC (50% of 35 to 320)

Set V/A

Adjust Switch

Set Remote

Process

Set Range Set Control

Max (178 A DC)

Min (35 A DC)

Adjust Optional Remote Control

0774 / Ref. 215 664 / Ref. 803 602

OM-4428 Page 37

SECTION 8 − OPERATING AUXILIARY EQUIPMENT

8-1. 120 Volt And 240 Volt Receptacles

1

3

4

1 120 V 20 A AC GFCI

Receptacle GFCI1
2 240 V 30 A AC Twistlock

Receptacle RC1
Receptacles supply 60 Hz single-

phase power at weld/power speed.
If a ground fault is detected, GFCI

2

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 Supplementary Protector CB1
4 Supplementary Protector CB2
CB1 protects RC1 and the genera-

tor winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset.

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

 If a supplementary protector

continues to open, contact

Factory Authorized Service

Agent.

 Generator power is not af-

fected 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 is available at GFCI1:

(240 V x 13 A) + (120 V x 7 A) =

4.0 kVA/kW

OM-4428 Page 38

191 624-A

8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)

 Place Process/Contactor switch

in Electrode Hot - Stick position
when using three-phase genera-

Single-Phase Power Connection

Three-Phase Power Connection

Remove plug
before inserting
leads. Reinstall
bushing.

5

6

7

9

8

12

! Close panel opening

if no connections are
made to generator.

Rear Of Panel

91 92 93

240V

120V

120V

240V

240V

240V

AC

Output

Volts

Amps

KVA/KW

Engine Speed 1850 RPM

Lead 42 connects to GROUND stud on
front of unit.

Jumper 42 is connected to 90 at factory.

Single
Phase

1

120/240

50
12

4

3

2

12

10

11

! Close panel

opening if no
connections
are made to
generator.

1-Phase

3-Phase

Three

Phase

3

240

48
20

60 HzFrequency

93

91

90

92

Tools Needed:

tor (see Section 7-3).

Single-Phase Generator Power

1 120/240 V 50 A Receptacle

RC5

RC5 is connected to the optional
three-phase generator 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 Supplementary Protector CB7
CB7 protects single-phase recep-

tacle RC5 and the load wires from
overload. If CB7 opens, all three­phase generator output stops and the
receptacle does not work.

Three-Phase Generator 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
Generator Power Guidelines
(see Section 14).

Remove generator 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 is connected to lead 90 at

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 Supplementary Protector CB7

User Terminals
Connect user-supplied leads to ter-

minals on CB7 and to the isolated
neutral terminal and grounding termi­nal as necessary.

 CB7 protects single-phase re-

ceptacle RC5 and the load wires

from overload. If CB7 opens, all

three-phase generator output

stops and the receptacle does

not work.

Reinstall generator power panel.

Ref. 197 399 / 802 332-B / 803 655

OM-4428 Page 39

8-3. Optional Generator Power Receptacles (Standard Models)

European Receptacle

5

6

Australian Receptacle

5

6

South African Receptacle

5

6

1

2

31

41

1 120 V 20 A AC GFCI

Receptacle GFCI1

2 240 V 16 A AC European

Receptacle RC1

3 240 V 15 A AC Australian

Receptacle RC1

4 240 V 15 A AC South African

Receptacle RC1

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

If a ground fault is detected, the
GFCI Reset button pops out and
the 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.

5 Supplementary Protector CB2
6 Supplementary Protector CB3
CB2 protects GFCI1 from overload.

If CB2 opens, GFCI1 does not
work. Press button to reset.

CB3 protects RC1 from overload. If
CB3 opens, RC1 does not work.
Press button to reset.

 If a supplementary protector

continues to open, contact
Factory Authorized Service
Agent.

 Generator power is not af-

fected 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 is available at GFCI1:

(240 V x 13 A) + (120 V x 7 A) =

4.0 kVA/kW

OM-4428 Page 40

191 624

8-4. Generator Power Receptacles (Export Models)

14 2 35

 Generator power is not affected by weld

output.

1 130 V 32 A AC Receptacle RC1
2 220 Volt 16 A AC Receptacle RC2
3 130 Volt 16 A AC Receptacle RC3
Receptacles supply 60 Hz single-phase

power at weld/power speed.
4 Supplementary Protector CB1
5 Supplementary Protectors CB2 And

CB3

CB1 protects RC1 and the generator wind­ing from overload. If CB1 opens, RC1 and
RC2 do not work. Place switch in On position
to reset.

CB2 protects RC2, and CB3 protects RC3
from overload. If a supplementary protector
opens, the receptacle does not work. Place
switch in On position to reset.

 If a supplementary protector continues

to open, contact Factory Authorized
Service Agent.

Ref. 204 258

Maximum output is 4 kVA/kW from RC1 and

2.2 kVA/kW from RC2 or RC3. Maximum
output from all receptacles is 4 kVA/kW.

Combined output of receptacles is limited to
4 kVA/kW output of generator. If maximum
output is exceeded, auxiliary equipment will
stop or not run properly.

EXAMPLE: If 20 A is drawn from RC1, only
8 A is available at each of the other
receptacles.

(110 V x 20 A) + ( 110 V x 8 A) + (110 V x 8
A) = 4 kVA/kW.

OM-4428 Page 41

SECTION 9 − MAINTENANCE (DEUTZ F4L2011−POWERED UNITS)

9-1. Maintenance Label (Deutz F4L2011-Powered Units)

OM-4428 Page 42

9-2. Routine Maintenance (Deutz F4L2011-Powered Units)

Manual

! Stop engine before maintaining.

Recycle engine

fluids.

 See Engine Manual and Maintenance Label

for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.

Every

8

Hours

Every

50

Hours

Every

100

Hours

Every

250

Hours

Every

500

Hours

Every

1000

Hours

 = Check  = Change  = Clean  = Replace
* To be done by Factory Authorized Service Agent

FUEL

WATER

 Fuel/Water Separator  Fuel Level  Oil Level  Oil, Fuel Spills

 Weld Terminals

 Battery Terminals  Air Cleaner Hoses  L’élément du filtre à air

1/2 in.

(13 mm)

 Unreadable Labels  Fan Belt Tension  Cooling System Spark Arrestor

 Weld Cables

 Oil  Oil Filter  FuelFilter

Reference

Section 5-8

Section 9-4

Engine
Manual,
Section 9-5

Section 5-8,
9-3, 9-7 and
Engine
Manual

Every

3000

Hours

Every

6000

Hours
or 5
Years

 Slip Rings*
 Brushes*

 Injectors*

 Engine Timing Belt

OR

FUEL

SLUDGE

 Inside Unit Valve Clearance*  Drain Sludge

OM-4428 Page 43

9-3. Checking Generator Brushes

Damaged Brushes

! Stop engine and let cool.

1 Generator Brush
Mark and disconnect leads at brush hold-

er cap. Remove brushes.
Replace brushes if damaged or if brush

material is at or near minimum length.

Minimum Length:

5/8 in (16 mm)

New Length: 1-1/4 in (32 mm)

Replace

1

Ref 215 158

Notes

OM-4428 Page 44

9-4. Servicing Air Cleaner (Deutz F4L2011-Powered Units)

2

Optional

Keep nozzle

2 in (51 mm)

from element.

Blow Inspect

41 3

! Stop engine.

NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged ele­ment is not covered by the warranty.

 The air cleaner primary element can

be cleaned but the dirt holding capac­ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean­ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment

5

damage when determining whether
to clean or replace the primary ele­ment.

If you decide to clean the primary ele­ment, we strongly recommend instal­ling an optional safety element to pro­vide additional engine protection.
Never clean a safety element. Re­place the safety element after servic­ing the primary element three times.

Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re­place primary element yearly or after six
cleanings.

1 Housing
2 Safety Element (Optional)
3 Primary Element
4 Dust Cap
5 Dust Ejector

To clean air filter:

Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.

NOTICE − Do not clean housing with air
hose.

Clean primary element with compressed
air only.

Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele­ment if it has holes or damaged gaskets.

Reinstall primary element and cap (dust
ejector down).

aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B

OM-4428 Page 45

9-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units)

! Stop engine and let cool.

1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt

covering cleanout hole.
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

2

1

material.

! Stop engine and let cool.

Reinstall cleanout plug.

Tools Needed:

OM-4428 Page 46

3/8 in

803 656 / Ref. 215 664

9-6. Adjusting Engine Speed (Deutz F4L2011-Powered Units)

1850 rpm Max.
(61.6 Hz)

1250 rpm
(41.5 Hz)

Standard Models

2

1

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 no
load speed with a tachometer or fre­quency meter (see table for no load
speeds). 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 Engine Speed Adjustment

Screw
2 Locking Nut
Loosen nut. Turn screw until engine

runs at weld/power speed. Tighten
nut.

 Do not set engine speed higher

than specified.

Models With Automatic Idle
(Optional)

3 Throttle Rod
4 Locknut
Loosen locknuts. Place engine

control switch in Run/Idle position.
Turn throttle rod until engine runs at

idle speed. Tighten locknuts.
5 Engine Speed Adjustment

Screw
6 Locknut
Place engine control switch in Run

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:

3/8, 7/16 in

4 3

5

6

803 657

OM-4428 Page 47

9-7. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units)

Tools Needed:

3

4

5

! 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 Primary Fuel Filter (Fuel/Water Sepa-

rator)
5 Petcock
6 Secondary Fuel Filter
7 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

1

maintenance label for oil/filter change in­formation.

To drain water from fuel system:

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

To replace primary fuel filter:

Turn filter counterclockwise. Remove filter.

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

Inspect fuel line, and replace if cracked or
worn.

6

2

7

803 657

To replace secondary fuel filter:

See engine manual.
Close doors.

To drain sludge from fuel tank:

! Beware of fire. Do not smoke and

keep sparks and flames away from
drained fuel. Dispose of drained fuel
in an environmentally-safe manner.
Do not leave unit unattended while
draining fuel tank.

! Properly lift unit and secure in a level

position. Use adequate blocks or
stands to support unit while drain­ing fuel tank.

Attach 1/2 ID hose to drain valve. Put metal
container under drain, and use screwdriver
to open sludge drain valve. Close valve
when sludge has drained. Remove hose.

OM-4428 Page 48

9-8. Overload Protection (Deutz F4L2011-Powered Units)

2

1

9

8

7

5

4

Ref. 803 657

! Stop engine.

 When a supplementary protector,

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 generator power is low or
stops entirely. If F2 opens, weld output
is low or stops entirely. 4 kVA/kW gener­ator power is still available.

3 Circuit Breaker CB4 (Not Shown)
4 Supplementary Protector CB5

(CC/CV Models Only)

5 Supplementary Protector CB6

(CC/CV Models Only)
6 Circuit Breaker CB10 (Not Shown)
7 Supplementary Protector CB11
8 Supplementary Protector CB12
9 Supplementary Protector CB13
10 Circuit Breaker CB14 (Not Shown)
CB4 protects the welding arc drive (dig)

circuit. If CB4 opens, electrode may
stick to the workpiece more frequently
during low voltage (short arc length)
conditions. CB4 automatically resets
when the fault is corrected.

CB5 protects the 24 volt ac output to re­mote receptacle RC14, and 24 volt out­put to field current regulator board PC1
(CC/CV models only). If CB5 opens,
weld output and 24 volt output to RC14
stops. On units with optional three­phase generator, generator power out­put at receptacle RC5 also stops if CB5
opens.

CB6 protects the 115 volt ac output to
remote receptacle RC14 (CC/CV mod­els only). If CB6 opens, 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 weld control circuit.
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 6-2). If CB11 opens on CV mod­els, weld output stops (generator power
is still available).

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

CB13 protects the engine control cir­cuit. If CB13 opens, the engine does not
crank.

CB14 protects throttle solenoid TS1 on
units with auto idle option. If CB14
opens, the engine does not run at idle
speed. CB14 automatically resets when
the fault is corrected.

Press button to reset supplementary
protector.

OM-4428 Page 49

SECTION 10 − MAINTENANCE (DEUTZ F3L912−POWERED UNITS)

10-1. Maintenance Label (Deutz F3L912-Powered Units)

OM-4428 Page 50

10-2. Routine Maintenance (Deutz F3L912-Powered Units)

Recycle engine

fluids.

! Stop engine before maintaining.

 See Engine Manual and Maintenance Label

for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.

Every

8

Hours

Every

50

Hours

Every

100

Hours

Every

250

Hours

Every

500

Hours

 = Check  = Change  = Clean  = Replace
* To be done by Factory Authorized Service Agent

FUEL

WATER

 Fuel/Water Separator  Fuel Level  Oil Level  Oil, Fuel Spills

 Weld Terminals

 Battery Terminals  Air Cleaner Hoses  Air Cleaner Element

1/2 in.

(13 mm)

 Unreadable Labels  Fan Belt Tension  Cooling System Spark Arrestor

Reference

Section 5-8,

Section
10-4

Engine
Manual,
Section
10-5

Every

1000

Hours

Every

3000

Hours

Every

6000

Hours
or 5
Years

 Weld Cables  Oil  Oil Filter

OR

 Slip Rings*
 Brushes*

Valve Clearance*

 Injectors*

 Engine Timing Belt

 Inside Unit  FuelFilter  Drain Sludge

SLUDGE

FUEL

Section 5-8,
10-3 and
Engine
Manual

OM-4428 Page 51

10-3. Checking Generator Brushes

Replace

Damaged Brushes

! Stop engine and let cool.

1 Generator Brush
Mark and disconnect leads at brush hold-

er cap. Remove brushes.
Replace brushes if damaged or if brush

material is at or near minimum length.

Minimum Length:

5/8 in (16 mm)

New Length: 1-1/4 in (32 mm)

1

Ref 215 158

Notes

OM-4428 Page 52

10-4. Servicing Air Cleaner (Deutz F3L912-Powered Units)

2

Optional

Keep nozzle

2 in (51 mm)

from element.

Blow Inspect

! Stop engine.

NOTICE − Do not run engine without air
cleaner or with dirty element. Engine

41 3

damage caused by using a damaged ele­ment is not covered by the warranty.

 The air cleaner primary element can

be cleaned but the dirt holding capac­ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean­ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment

5

damage when determining whether
to clean or replace the primary ele­ment.

If you decide to clean the primary ele­ment, we strongly recommend instal­ling an optional safety element to pro­vide additional engine protection.
Never clean a safety element. Re­place the safety element after servic­ing the primary element three times.

Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re­place primary element yearly or after six
cleanings.

1 Housing
2 Safety Element (Optional)
3 Primary Element
4 Dust Cap
5 Dust Ejector

To clean air filter:

Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.

NOTICE − Do not clean housing with air
hose.

Clean primary element with compressed
air only.

Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele­ment if it has holes or damaged gaskets.

Reinstall primary element and cap (dust
ejector down).

aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B

OM-4428 Page 53

10-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units)

! Stop engine and let cool.

1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt

covering cleanout hole.
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

2

1

material.

! Stop engine and let cool.

Reinstall cleanout plug.

Tools Needed:

OM-4428 Page 54

3/8 in

803 656 / Ref. 215 664

10-6. Adjusting Engine Speed (Deutz F3L912-Powered Units)

Engine Speed

(No Load)

Weld/Power

2

1

RPM (Hz)

1850

(61.6 Hz)

! Stop engine.

Engine speeds have been factory
set and should not require adjust­ment. After tuning engine, check
engine speeds with a tachometer.
See table for proper no load speed.
If necessary, adjust speed as fol­lows:

1 Speed Adjustment Screw
2 Locknut
Loosen nut. Start engine.
Turn screw until engine runs at

weld/power speed. Tighten locknut.

 Do not set engine speed higher

than specified.

! Stop engine.

Close side door.

10-7. Servicing Optional Ether Starting Aid (Deutz F3L912-Powered Units)

! Stop engine.
! Improper handling or expo-

sure to ether can harm your
health. Follow manufactur­er’s safety instructions on
cylinder.

If engine does not start in cold
weather, check ether cylinder as
follows:

Remove cylinder from valve.

1

3

1 Ether Cylinder
2 Valve
3 Scale
Weigh cylinder to see if it is empty.
Be sure atomizer is not plugged and

valve fitting is clean.
Replace cylinder according to

Section 5-5.

Tools Needed:

9/16, 7/8 in

803 658 / 134 730-C

(935 g) (425 g)

Full Empty

15 oz33 oz

2

ether2 7/96 − ST-153 382-A / Ref. 202 705 / S-0692

OM-4428 Page 55

10-8. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units)

Tools Needed:

6

3

4

! 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 Primary Fuel Filter (Fuel/Water Sepa-

rator)
5 Petcock
6 Secondary Fuel Filter
7 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

1

7

maintenance label for oil/filter change in­formation.

To drain water from fuel system:

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

To replace primary fuel filter:

Turn filter counterclockwise. Remove filter.

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

Inspect fuel line, and replace if cracked or
worn.

5

2

803 658

To replace secondary fuel filter:

See engine manual.
Close doors.

To drain sludge from fuel tank:

! Beware of fire. Do not smoke and

keep sparks and flames away from
drained fuel. Dispose of drained fuel
in an environmentally-safe manner.
Do not leave unit unattended while
draining fuel tank.

! Properly lift unit and secure in a level

position. Use adequate blocks or
stands to support unit while drain­ing fuel tank.

Attach 1/2 ID hose to drain valve. Put metal
container under drain, and use screwdriver
to open sludge drain valve. Close valve
when sludge has drained. Remove hose.

OM-4428 Page 56

10-9. Overload Protection (Deutz F3L912-Powered Units)

2

1

9

8

7

4

5

! Stop engine.

 When a supplementary protector, cir-

cuit 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 gener­ator power is low or stops entirely. If F2
opens, weld output is low or stops entirely.
4 kVA/kW generator power is still available.

3 Circuit Breaker CB4 (Not Shown)
4 Supplementary Protector CB5

(CC/CV Models Only)

5 Supplementary Protector CB6

(CC/CV Models Only)
6 Circuit Breaker CB10 (Not Shown)
7 Supplementary Protector CB11
8 Supplementary Protector CB12
9 Supplementary Protector CB13
10 Circuit Breaker CB14

(Not Shown)
CB4 protects the welding arc drive (dig) cir-

cuit. If CB4 opens, electrode may stick to
the workpiece more frequently during low
voltage (short arc length) conditions. CB4
automatically resets when the fault is cor­rected.

CB5 protects the 24 volt ac output to remote
receptacle RC14, and 24 volt output to field
current regulator board PC1 (CC/CV mod­els only). If CB5 opens, weld output and 24
volt output to RC14 stops. On units with op­tional three-phase generator, power output
at receptacle RC5 also stops if CB5 opens.

CB6 protects the 115 volt ac output to re­mote receptacle RC14 (CC/CV models
only). If CB6 opens, 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 weld control circuit. 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 6-2). If
CB11 opens on CC/CV models, weld output
stops (generator power is still available).

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

CB13 protects the engine control circuit. If
CB13 opens, the engine does not crank.

CB14 protects fuel solenoid FS1. If CB14
opens, the engine does not start. CB14 au­tomatically resets when the fault is cor­rected.

Press button to reset supplementary pro­tector.

Ref. 803 658

OM-4428 Page 57

SECTION 11 − TROUBLESHOOTING

11-1. Troubleshooting

A. Welding − CC Models

Trouble Remedy

No weld output; generator power output
okay at ac receptacles.

No weld output or generator power out­put at ac receptacles.

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

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 5-11 and 6-1).

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-11).

Check fuse F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service Agent
check integrated rectifier SR2 and the rotor.

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

Disconnect equipment from generator power receptacles during start-up.

Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1 (see Sec­tion 9-8 or 10-9).

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 brushes and slip rings.

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

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 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

Electrode sticks to the workpiece more
frequently during low voltage (short arc
length) conditions.

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 Remote position.

OM-4428 Page 58

Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8
or 10-9). Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and
SR5.

Have Factory Authorized Service Agent check control relay CR7.

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-11).

Reset supplementary protector CB11 (see Section 9-8 or 10-9). Have Factory Authorized Service Agent
check control relay CR7.

Repair or replace remote control device.

Have Factory Authorized Service Agent check OCV control circuit.

B. Welding − CC/CV Models

Trouble Remedy

No weld output; generator power output
okay at ac receptacles.

No weld output or generator power out­put at ac receptacles.

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

Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
On/Off Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14
(see Sections 5-12 and 7-1).

Check position of Ampere Range switch.

Check position of optional Polarity switch or Polarity/AC switch.

Reset supplementary protector CB11 (see Section 9-8 or 10-9).

Reset supplementary protector CB5 (see Section 9-8 or 10-9). Check for faulty remote device con­nected to RC14.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-12).

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

Check fuse F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service Agent
check brushes and slip rings, weld excitation circuit, field current regulator board PC1, and the rotor.

Disconnect equipment from generator power receptacles during start-up.

Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). 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.

Have Factory Authorized Service Agent check brushes and slip rings.

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

Check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent check field current regulator board PC1, and PC1 voltage feed­back circuit.

Voltage/Amperage control does not
work when welding in Stick mode.

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

Electrode sticks to the workpiece more
frequently during low voltage (short arc
length) conditions.

Low open-circuit voltage. Check engine speed, and adjust if necessary.

No remote fine amperage or voltage
control.

Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere
Range switch in highest range.

Check engine speed, and adjust if necessary.

Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8
or 10-9). Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and
SR5.

Check position of Process/Contactor switch.

Place Voltage/Amperage Adjust switch in Remote position.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-12).

Repair or replace remote control device.

Have Factory Authorized Service Agent check PC1 current sensing leads (36 and 37), and connections.

Constant speed wire feeder does not
work.

Reset supplementary protector CB5 or CB6 (see Section 9-8 or 10-9).

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-12).

Repair or replace wire feeder.

OM-4428 Page 59

Trouble Remedy

Low CV weld output. Set Ampere Range switch to highest range.

Increase Voltage/Amperage Adjust Control setting.

Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.

Repair or replace remote control device.

Have Factory Authorized Service Agent check Amperage/Voltage Adjust Control R1, and field current
regulator board PC1.

C. Standard Generator Power

Trouble Remedy

No generator power output at ac recep­tacles; weld output okay.

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

High output at generator power ac re­ceptacles.

Low output at generator power ac recep­tacles.

Reset receptacle supplementary protectors.

Reset GFCI receptacle.

Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, and the rotor.

Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1 .

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 generator power field current resistor R3.

Check engine speed, and adjust if necessary.

Check fuse F1, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service Agent
check integrated rectifier SR1, resistor R3, and capacitor C9.

D. Optional Three-Phase Generator Power (CC/CV Models Only)

Trouble Remedy

No or low output at optional three­phase generator/receptacle RC5.

Place Process/Contactor switch in Weld Terminals Always On - Stick position (see Section 7-3).

Reset supplementary protector CB7(see Section 8-2).

Reset supplementary protector CB5 (see Section 9-8 or 10-9).

High output at optional three-phase
generator/receptacle RC5.

Erratic output at optional three-phase
generator/receptacle RC5.

OM-4428 Page 60

Check engine weld/power speed, and adjust if necessary (see Section 9-6 or 10-6).
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 9-6 or 10-6).

Have Factory Authorized Service Agent check field current regulator board PC1, and PC1 voltage
feedback circuit.

Have Factory Authorized Service Agent check brushes and slip rings, and 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 9-8
or 10-9). Have Factory Authorized Service Agent check engine wiring harness and components.

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check control relay CR1, control relay CR5, time delay relay
TD1, and Engine Control switch S1.

Engine cranks but does not start. Check fuel level.

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

Have Factory Authorized Service Agent check time delay relay TD1, control relay CR5, fuel pump,
and fuel solenoid FS1.

Air in fuel system. See engine manual.

Engine starts, but stops after 30 sec­onds.

Engine hard to start in cold weather. Use starting aid switch (see Section 6-1 or 7-1).

Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 5-8). Automatic shutdown system is inhibited for 30 seconds after
start-up.

Have Factory Authorized Service Agent check time delay relay TD1, and control relay CR5.

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 9-1 or 10-1).

Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant

Engine slowly stopped and cannot be
restarted.

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

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).

temperature is too high (see Section 5-8). Automatic shutdown system is inhibited for 30 seconds after
start-up.

See engine manual.

Check fuel level.

Check engine air and fuel filters (see Sections 9-4 and 10-4, or Sections 9-7 and 10-8).

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).

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

Check for obstructed throttle solenoid.

CC models: place Stick/TIG Selection switch in Stick position.
CC/CV models: place Process/Contactor switch in any position but Remote On/Off Switch Required­TIG.

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

Check for obstructed throttle solenoid.

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

Dry engine according to run-in procedure (see Section 13).

OM-4428 Page 61

SECTION 12 − ELECTRICAL DIAGRAMS

Figure 12-1. Circuit Diagram For CC Welding Generator (Deutz F4L2011-Powered Units)

OM-4428 Page 62

OM-4428 Page 63

215 221-E

Figure 12-2. Circuit Diagram For CC Welding Generator (Deutz F4L2011-Powered Units) (Export Models)

OM-4428 Page 64

OM-4428 Page 65

235 275-A

Figure 12-3. Circuit Diagram For CC/CV Welding Generator (Deutz F4L2011-Powered Units)

OM-4428 Page 66

215 806-E

OM-4428 Page 67

OM-4428 Page 68

Figure 12-4. Circuit Diagram For CC/CV Welding Generator

(Deutz F4L2011-Powered Units) (Export Models)

OM-4428 Page 69

235 276-A

Figure 12-5. Circuit Diagram For CC Welding Generator (Deutz F3L912-Powered Units)

OM-4428 Page 70

OM-4428 Page 71

215 807-D

Figure 12-6. Circuit Diagram For CC/CV Welding Generator (Deutz F3L912-Powered Units)

OM-4428 Page 72

OM-4428 Page 73

215 808-D

13-1. Wetstacking

1

SECTION 13 − RUN-IN PROCEDURE

NOTICE − Do not perform run-in
procedure at less than 20 volts
weld output and do not exceed duty
cycle or equipment damage may
occur.

1 Welding Generator

2

Run diesel engines near rated volt­age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name­plate, rating label, or specifications
section in this manual to find rated
voltage and current.

NOTICE − Do not idle engine longer
than necessary. Piston rings seat
faster if engine runs at weld/power
rpm, and the welding generator is
kept loaded during run-in.

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 2007−04

OM-4428 Page 74

13-2. Run-In Procedure Using Load Bank

4

2

3

Stop engine.

Do not touch hot exhaust pipe,
engine parts, or load bank/grid.

Keep exhaust and pipe away
from flammables.

NOTICE − Do not perform run-
in procedure at less than 20

1

volts weld output and do not
exceed duty cycle or equip­ment damage may occur.

1 Load Bank
Turn all load bank switches Off. If

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

2 Welding Generator
Place A/V range switch in 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 voltage and
current of generator (see name­plate, rating label, or the specifi­cations section in this manual).

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

NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.

It is recommended to run the weld­ing generator for two hours mini­mum and up to four hours under
load. Place A/V control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.

Stop engine and let cool.

4 Engine Exhaust Pipe
Repeat procedure if wetstacking

is present.

S-0683

OM-4428 Page 75

13-3. Run-In Procedure Using Resistance Grid

6

2

3

4

+

5

Stop engine.

Do not touch hot exhaust pipe,
engine parts, or load bank/grid.

Keep exhaust and pipe away
from flammables.

NOTICE − Do not perform run-
in procedure at less than 20
volts weld output and do not
exceed duty cycle or equip­ment damage may occur.

1 Resistance Grid
Use grid sized for generator rated

1

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

mum position, A/V control in 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 voltage and
current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).

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

NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.

It is recommended to run the weld­ing generator for two hours mini­mum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.

OM-4428 Page 76

Stop engine and let cool.

6 Engine Exhaust Pipe
Repeat procedure if wetstacking is

present.

S-0684

SECTION 14 − GENERATOR POWER GUIDELINES

 The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.

14-1. Selecting Equipment

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

 Be sure equipment has double

1

2

3

OR

gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577

insulated symbol and/or word­ing on it.

! Do not use 2-prong plug un-

less equipment is double in­sulated.

14-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

2

3

! Always ground generator

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

! Also see AWS Safety &

Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied)
3 Metal Vehicle Frame
Connect cable from equipment

ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.

 Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

! Bed liners, shipping skids,

and some running gear insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equip-

ment grounding terminal to

bare metal on the vehicle

frame as shown.

! If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

S-0854

OM-4428 Page 77

14-3. Grounding When Supplying Building Systems

1 2

GND/PE

2

3

1 Equipment Grounding

Terminal
2 Grounding Cable
Use #10 AWG or larger insulated

copper wire.
3 Ground Device

 Use ground device as stated in

electrical codes.

! Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

! Also see AWS Safety &

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

14-4. How Much Power Does Equipment Require?

3

2

1

3

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 14-8).

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

peres at 115 volts, calculate its run­ning power requirement in watts.

4.5 A x 115 V = 520 W
The load applied by the drill is 520

watts.
Example 2: If three 200 watt flood

lamps are used with the drill from Ex­ample 1, add the individual loads to
calculate total load.

(3 x 200W) + 520 W = 1120 W
The total load applied by the three

flood lamps and drill is 1120 watts.

OM-4428 Page 78

S-0623

14-5. 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

14-6. 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-4428 Page 79

14-7. 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-4428 Page 80

14-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

Motor Start

Code

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

G H J K L M N P

1 Motor Start Code
2 Running Amperage

4
1
3

VOLTS AMPS

CODE 60

HP

AC MOTOR

230 2.5

M

1/4

Hz
PHASE

1

2

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.

(kVA/HP x HP x 1000) / Volts =

Starting Amperage

Example: Calculate starting amper­age required for a 230 V, 1/4 HP mo­tor with a motor start code of M.

Volts = 230, HP = 1/4, kVA/HP =

11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2

amperes.

S-0624

14-9. How Much Power Can Generator Supply?

1

2

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-4428 Page 81

14-10. Typical Connections To Supply Standby Power

123

Utility

Electrical

Service

Transfer Switch

5

Essential

Loads

Fused

Disconnect

Switch

(If Required)

4

Welding

Generator

Output

! Have only qualified persons

perform these connections
according to all applicable
codes and safety practices.

! Properly install and ground

this equipment according to
its Owner’s Manual and na­tional, state, and local codes.

 Customer-supplied equipment

is required if generator will sup­ply standby power during
emergencies or power out­ages.

1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load

from electric utility service to the
generator. Transfer load back to
electric utility when service is re­stored.

Install correct switch (customer­supplied). Switch rating must be
same as or greater than the branch
overcurrent protection.

3 Fused Disconnect Switch
Install correct switch (customer-

supplied) if required by electrical
code.

4 Welding Generator Output
Generator output voltage and wir-

ing must be consistent with regular
(utility) system voltage and wiring.

Connect generator with temporary
or permanent wiring suitable for the
installation.

Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low volt­age and frequency.

5 Essential Loads
Generator output may not meet the

electrical requirements of the prem­ises. If generator does not produce
enough output to meet all require­ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 14-4).

OM-4428 Page 82

14-11. 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

Load (Watts) 4 6 8 10 12 14

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 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

OM-4428 Page 83

 Hardware is common and not

available unless listed.

 A Deutz F4L2011 engine-pow-

ered unit is shown below. See
insert for parts specific to a
Deutz F3L912-powered unit.
Parts not related to the engines
are the same in both units.

SECTION 15 − PARTS LIST

15

12

14

11

9

10

12

99

16

17

18

19

92

20

21

22

107

3

101

13

4

100 (Fig. 15-7)

65

8

7

2

1

106

125

105

104 (FIG. 15-4 OR 15-5)

OM-4428 Page 84

103

98 (FIG. 15-2 OR 15-3)

95 (CC ONLY)

96

97 (CC ONLY)

102

CC CC Models Only
CV CC/CV Models Only

Figure 15-1. Main Assembly

90

91

93

94 (CC ONLY)

 A Deutz F4L2011 en-

gine-powered unit is
shown below. See in­sert for parts specific to
a Deutz F3L912-pow­ered unit. Parts not re­lated to the engines are
the same in both units.

121

25

24

23

27

26

28

29

119

118

123

113

35 (Fig. 15−6)

31

Deutz F3L912 Engine

29

33

110

117

108

109

112

116

111

16

120

2

124

17

115

68

69

67

65

70

60

63

62

61

114

58

59

56
57

122

44

45

53

54

47

46

48

81

126

35 (Fig. 15-6)

84

82

83

43

33

42

86

87

38

30

39

32

37

36

2

85

40

66

41

34

65

64

61

60

63

62

59

57

53

55

56

58

54

70

80

72

67
68

69

73

2

71

50

51

2

49

52

2

74

75

76

90

89

88

79

78

77

803 659 / 803 665

OM-4428 Page 85

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 15-1. Main Assembly

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

1 ♦199 294 PANEL, gen LH ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 225 120 LABEL, warning moving parts can cause injury 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 +189 828 PANEL, engine side 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦+199 301 PANEL, engine side ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦212 570 Baffle, engine side (export models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4Z1♦201 520 REACTOR, ac environmental 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 1T 038 621 BLOCK, term 30A 4 pole frict term str 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

6 081 499 BRACKET, mtg strip terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 206 352 BRACE, front to center upright 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203 260 LABEL, caution do not use ether 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 SR4, SR5 215 909 RECTIFIER 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 CB4 045 061 CIRCUIT BREAKER, auto reset 24vdc 7 amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 201 697 PAN, reactor and rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 T1 201 613 TRANSFORMER w/bracket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 T1 ♦205 636 TRANSFORMER w/bracket (environmental coating) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 173 352 EXTRUSION, rubber clamp/bulb (order by ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 189 708 FIREWALL, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 191 307 COVER, plate 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 191 829 HOSE, air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 189 763 BRACKET, mtg air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 189 764 AIR CLEANER, intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

18 189 464 SEAL, weather lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173 909 HOSE, sae .312 id x .560 od x 24.000 (order by ft) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 201 658 UPRIGHT, center assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 +200 999 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 ♦+203 382 BASE e-coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 196 220 BRACKET, hold down fuel tank rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 192 362 BRACKET, mtg nyl 1/2 conduit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 +201 934 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 ♦+202 640 COVER, top ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 189 052 GROMMET, plastic neck filler fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 190 198 CAP, tank screw-on 3.500 in w/vent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 192 041 LABEL, use diesel fuel only (Wordless Label) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 222 513 LABEL, warning falling equipment can cause serious 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 224 265 LABEL, warning hot exhaust parts do not touch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 105 734 PIPE, muffler extension elbow 1.875 OD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 201 592 PIPE, exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 201 851 COVER, radiator access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 191 354 SUPPORT, cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 202 633 SUPPORT, cover e-coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 010 875 CLAMP, muffler 2.000 dia u pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 200 730 MANIFOLD, exhaust muffler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 Figure 15-6 GENERATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 191 577 GUARD, starter (Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 191 809 BRACKET, mtg engine LH (Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 190 951 EDGE TRIM, styel tl750-b2 x 1/16 black w/clips 1.625 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 191 817 BAFFLE, air (Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 213 877 ENGINE, Deutz dsl elec F4L2011 (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*067 265 FILTER, oil (engine) (Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*192 744 FILTER, fuel spin-on (Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*066 217 FILTER, fuel secondary (Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*195 745 SWITCH, oil pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*195 746 SENDER, coolant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-4428 Page 86

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 15-1. Main Assembly (Continued)

♦174 064 IDLE, solenoid assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦175 937 BRACKET, support solenoid 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 *067 266 BELT, blower (Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 201 714 BOX, air intake (Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 201 748 UPRIGHT, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 ♦202 638 UPRIGHT, rear ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 190 206 CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 108 081 TERMINAL PROTECTOR, battery post mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 190 207 CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 203 430 BRACKET, battery holddown 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 190 897 BATTERY, stor 12V 650crk 110rsv gp 24 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 201 006 BOLT, j stl .312−18 x 8.500 pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 +201 183 COVER, battery access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 202 639 COVER, battery access ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 168 385 LABEL, warning battery explosion can blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 +215 252 GUARD, belt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 199 849 SCREW, 625-11 x 4.00hexhd pln gr 5 pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 071 731 WASHER, flat .656 ID x 2.250 OD x .187T stl pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 191 812 BRACKET, mtg engine RH (Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 071 890 RETAINER, mount eng/gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 071 730 TUBING, stl .875 OD x 12ga wall x 2.500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 083 476 MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 135 205 NUT, 625-11 .94hex .76H stl pld elastic stop nut 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 507 HOSE, oil drain assy 20 in (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 165 271 VALVE, oil drain 3/8-18NPTF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 176 529 FITTING, hose brs barbed fem 1/2tbg x 3/8NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 113 854 HOSE, SAE .500 ID x .780 OD xc oil (order by ft) 2ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 176 528 FITTING, hose brs barbed elbow fem 1/2 tbg x 1/2 NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 173 336 FITTING, adapter oil drain 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 WASHER, oil drain (available through engine manufacturer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 219 229 BRACKET, mtg solenoid (Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 206 297 BASE, fuel filter assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 145 282 FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 196 465 HOSE, SAE .312 ID X .560 OD X 23.00 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200 032 HOSE, SAE .312 ID X .560 OD X 38.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 *192 744 FILTER, fuel spin-on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 190 992 KEEPER, latch engine access door 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 190 076 CHANNEL, stiffener engine access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 ♦202 635 CHANNEL, stiffener engine access e-coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 199 592 LATCH, paddle series 20 (black) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 215 233 LABEL, diesel engine maintenance Deutz (Wordless Label) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 +200 989 DOOR, engine access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 +210 736 DOOR, engine access ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 189 975 HINGE, door access 180deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 208 141 STOP, door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 189 826 PANEL, rocker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 199 298 PANEL, rocker ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 189 827 PANEL, gen RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 199 300 PANEL, gen RH ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 191 626 BUMPER, door engine access 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 218 087 TANK, fuel (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 124 253 BUSHING, tank fuel 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

83 189 912 FITTING, stl barbed elbow w/.047 in orf zinc pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 189 909 FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 189 913 FITTING, stl barbed elbow zinc pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 190 142 SENDER, fuel gauge 9.7500 deep tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 189 910 FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-4428 Page 87

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 15-1. Main Assembly (Continued)

88 189 908 VALVE, drain fuel 180deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 181 572 BUSHING, tank fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 191 446 EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) 6ft. . . . . . . . . . . . . . . . . . . . . . . . . .

91 191 897 BRACKET, mtg unit 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 218 086 BRACKET, hold down fuel tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 224 266 LABEL, warning do not weld on base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 190 179 PANEL, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 R4

C

191 292 RESISTOR, WW fxd 375W 50 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

96 R2 189 699 RESISTOR, WW tap 375W 10 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 R3

C

189 699 RESISTOR, WW tap 375W 10 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

98 Figure 15-2, Figure 15-3 CONTROL BOX ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 189 731 FIREWALL, lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 Figure 15-7 MAIN RECTIFIER ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 191 448 TOP, cover front upright 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 ♦199 305 TOP, cover front upright ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 +201 750 UPRIGHT, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 ♦+202 637 UPRIGHT, front ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 233 953 LABEL, warning general precautionary csa 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 Figure 15-4, Figure 15-5 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105 ♦202130 XFMR, current sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106
107 PC1

C

193 453 BRACKET, mtg box fcr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V

C

207 397 MODULE, field current regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V

190 058 NUT, .250-20 u-nut multi-thread 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049 525 NUT, 312-18 u-nut multi-thread 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215 631 KIT, label (includes safety & informational labels) (CC models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215 632 KIT, label (includes safety & informational labels) (CC/CV models) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

216 995 KIT, label (includes safety & informational labels) (CC export models). . . . . . . . . . . . . . . . . . . . .

(Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

216 994 KIT, label (includes safety & informational labels) (CC/CV export models). . . . . . . . . . . . . . . . . . . . .

(Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

216 991 KIT, label (includes safety & informational labels) (CC export models). . . . . . . . . . . . . . . . . . . . .

(Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

216 990 KIT, label (includes safety & informational labels) (CC/CV export models). . . . . . . . . . . . . . . . . . . . .

(Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108 199 063 ENGINE, Deutz dsl elec F3L912 d0392−166/00 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109 *064 677 FILTER, oil (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110 *066 271 BELT, blower (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111 *195 745 SWITCH, pressure oil 1.5 bar nc cont 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112 *195 746 SENDER, coolant temp & 130 degee C switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 194 135 BACKPLATE, Deutz F3L912 engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 194 572 SUPPORT, front engine (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115 FS1 141 346 SHUTDOWN KIT, engine (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116 118 452 FTG, adapter oil drain (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

117 193 313 MANIFOLD, exhaust muffler (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

118 194 496 BAFFLE, lower air outlet (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

119 194 497 BAFFLE, upper air outlet (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 194 500 BAFFLE, air intake (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121 194 485 HOSE, air cleaner (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

122 +201 714 BOX, air intake (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

123 195 560 GUARD, starter hole (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124 194 467 WASHER, flat 6.25idx11.50odx.062t buna n 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

125 212 944 LABEL, stick overlap weld ranges 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

126 233 088 LABEL, danger using a generator indoors can kill you in minutes (unit) 1. . . . . . . . . . . . . . . . .

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts. ♦optional

C

CC models only.

C

C

C/CV models only.

V

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-4428 Page 88

14

6

3

7

2

4

18

25

23

21

17

8

26

1

15

11

19

16

13

12

24

10

9

22

20

5

Figure 15-2. Control Box Assembly − CC Models

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 15-2. Control Box Assembly − CC Models (Figure 15-1 Item 98)

1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 046 432 HOLDER, fuse mintr .250 x 1.250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 201 077 CONTROL BOX, lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 201 078 CONTROL BOX, rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 201 079 COVER, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 C12 191 944 CAPACITOR, polyp met film 10. uf 250 vac 10% 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215 054 HARNESS, control box, weld control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 CR7 188 636 RELAY, OCV control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

9 SR1, SR2 035 704 RECTIFIER, integ 40A 800V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CR5 223 710 RELAY, Encl 12vdc Dpst−no 25a 6pin Flange 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S5 011 609 SWITCH, tgl spdt 15a 125vac on−none−on spd term chr. . . . . . . . . . . . . . . . . . . .

(located on front panel, see Figure 15-4) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S6 011 622 SWITCH, tgl 3pdt 15a 125vac on−none−on spd term. . . . . . . . . . . . . . . . . . . .

(located on front panel, see Figure 15-4) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC4 047 483 CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . . . . .

RC3 158 466 CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . . . . .

RC1 135 133 CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177 859 CONN, body 5 terminal (to engine control switch S1) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 316 CONN, rect univ 039 6p/s 3row plug cable lkg 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

092 670 CONN, rect univ 084 3p/s 1row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 CB11, 12, 13 139 266 SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac 3. . . . . . . . . . . . . .

803 660-C

Quantity

OM-4428 Page 89

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 15-2. Control Box Assembly − CC Models (Continued)

215 013 HARNESS, unit weld control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 158 465 CONN, rect univ 084 12p/s 3row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 654 SEAL, wire univ 12p/s 3row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 114 063 CONN, rect univ 084 4p/s 1row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 309 CLIP, snap in .630 bundle .250 hole .248 thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 177 136 CLAMP, capacitor 1.375dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 C9 087 110 CAPACITOR, elctlt 240uf 200VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 R6 141 424 RESISTOR, ww fxd 30 w 25 ohm faston te 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 PC7 ♦195 706 MODULE, pull to idle, two output, 7 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 CR4 ♦113 247 RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

17 CR6 ♦090 104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 CR3 090 104 RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . .

215 660 HARNESS, engine control (Deutz F4L2011 engine) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . .

19 D1/C1 189 701 DIODE/CAPACITOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

148 850 SOCKET, relay 5 pin 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 114 062 CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173 916 HOUSING, contact 10-pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 CR1 214 876 RELAY, encl 6vdc spst 35a/14vdc 5 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 CB14 ♦205 927 CIRCUIT BREAKER, auto reset 12vdc 12 amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

205 931 HARNESS, engine control (Deutz F3L912 engine) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

148 850 SOCKET, relay 5 pin 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 114 062 CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 CR1 214 876 RELAY, encl 6vdc spst 35a/14vdc 5 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 CB14 205 927 CIRCUIT BREAKER, auto reset 12vdc 12 amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 CR8 ♦197 325 RELAY, encl 12vdc spst 70a 4pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 TD1 214 928 TIMER, delay on make/break open 30 sec 12vdc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 CR9 090 104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

235 251 HARNESS, fuel shutdown solenoid (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 R7 235 250 RESISTOR, hsc 30 w 3 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

♦Optional
*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4428 Page 90

4

5

24

6

7

3

8

9

25

2

1

12

13

23

22

18

19

20

21

14

16

17

10

11

15

Figure 15-3. Control Box Assembly − CC/CV Models

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 15-3. Control Box Assembly − CC/CV Models (Figure 15-1 Item 98)

1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 046 432 HOLDER, fuse mintr .250 x 1.250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 201 077 CONTROL BOX, lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 201 078 CONTROL BOX, rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 CR3 090 104 RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . .

6 CR8 ♦197 325 RELAY, encl 12vdc spst 70a 4pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 CR1 214 876 RELAY, encl 6vdc spst 35a/14vdc 5 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CR6 ♦090104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

10 CB14 205 927 CIRCUIT BREAKER, auto reset 12vdc 12 amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

12 CR5 223 710 RELAY, encl 12vdc dpst−no 25a 6pin flange 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 PC7 ♦195 706 MODULE, pull to idle, two output, 7 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 SR1 035 704 RECTIFIER, integ 40A 800V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 201 079 COVER, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 CR4 ♦113 247 RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

17 PC9 192 224 CIRCUIT CARD ASSY, display 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 134 201 STAND-OFF, support pc card 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 TD1 214 928 TIMER, delay on make/break open 30 sec 12vdc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 C9 087 110 CAPACITOR, elctlt 240uf 200VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 177 136 CLAMP, capacitor 1.375dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 D1/C1 189 701 DIODE CAPACITOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

803 661-C

Quantity

OM-4428 Page 91

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 15-3. Control Box Assembly − CC/CV Models (Continued)

23 CB11, 12, 13 139 266 SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac 3. . . . . . . . . . . . . .

24 CR9 090 104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215 377 HARNESS, control box, cv weld control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC4 047 483 CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . . . . .

RC3 158 466 CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . . . . .

RC1 135 133 CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg 1. . . . . . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S6 193 324 SWITCH, rotary 6 position gold contacts. . . . . . . . . . . . . . . . . . .

(located on front panel, see Figure 15-5) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S5 011 609 SWITCH,tgl spdt 15a 125vac on−none−on spd term chr. . . . . . . . . . . . . . . . . . . .

(located on front panel, see Figure 15-5) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 316 CONN, rect univ 039 6p/s 3row plug cable lkg 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177 859 CONN, body 5 terminal (to engine control switch S1) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 183 CONN, rect cinch 18 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196 602 PLUG, cavity 18,30 position cinch connector 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196 603 SEAL, switch 6 position rotary .250 shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141 450 CONN, rect metrmate 10skt 1row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

206 024 HARNESS, engine control (Deutz F4L2011 engine) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 114 062 CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173 916 HOUSING, contact 10-pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

205 931 HARNESS, engine control (Deutz F3L912 engine) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 114 062 CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185 655 SEAL, wire univ 15P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

235 251 HARNESS, fuel shutdown solenoid (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 R7 235 250 RESISTOR, hsc 30 w 3 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional
*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4428 Page 92

 Hardware is common and

not available unless listed.

4

3

5

2

1

6

7

8
9

10

38

39

37

36

40

41

42

33

34

35

32

31

29

28

30

11

12

13

14

15

16

17

18

19

21

20

22

27

26

25

24

23

Figure 15-4. Panel, Front w/Components − CC Models

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 15-4. Panel, Front w/Components − CC Models (Figure 15-1 Item 104)

1 215 663 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 215 014 PANEL, engine/weld control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦220544 PANEL, engine/weld control ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S3 208278 SWITCH, range/changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4428 Page 93

803 662

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 15-4. Panel, Front w/Components − CC Models (Continued)

192 558 HARNESS, range (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC6 148 439 HOUSING, rect univ 084 4p/s 1 row rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R1 188 635 RHEOSTAT, WW 300W 34 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 202 209 SPACER, nylon 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 S6 011 622 SWITCH, tgl DPDT 15A 125VAC (included in control box harness,. . . . . . . . . . . . . . .

see Figure 15-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 S5 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in. . . . . . . . . . . . . . .

control box harness, see Figure 15-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 RC13 032 897 RECEPTACLE, twlk grd 2P3W 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 S2 ♦021 467 SWITCH, tgl spst 3a 250v off−none−(on) spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 S1 212 436 SWITCH, ignition 4 position w/handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 553 CLIP, circuit breaker retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 CB1 201 083 SUPPLEMENTARY PROTECTOR, man reset 2p 20a 250vac. . . . . . . . . . . .

(European Receptacle) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 CB1 ♦202 683 SUPPLEMENTARY PROTECTOR, man reset 2p 40a 240vac. . . . . . . . . . .

(export models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦197 527 GUARD, circuit breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB2, CB3 ♦201 083 SUPPLEMENTARY PROTECTOR, man reset 2p 20a 250vac 2. . . . . . . . . . . . . . . . . .

201 109 HARNESS, generator power (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CB2 093 996 SUPPLEMENTARY PRO, man reset 1p 20a 250vac frict 3. . . . . . . . . . . . . . . . . . . . . . . . .

14 GFCI1 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

15 RC1 147 632 RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦201 053 HARNESS, generator power (European Receptacle) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . .

13 CB2 ♦093 996 SUPPLEMENTARY PRO, man reset 1p 20a 250vac frict 1. . . . . . . . . . . . . . . . . . . . . . . .

13 CB3 ♦139 266 SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac 1. . . . . . . . . . . . . . . . . . . .

14 GFCI1 ♦151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . .

♦213 577 HARNESS, generator power (export models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦189 549 BLOCK, term assy standard 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦038 620 LINK, jumper term block 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 RC1 ♦176 355 RECEPTACLE, str 2p3w 16a 220v flange mtg (European Receptacle) 1. . . . . . . . . . . . .

15 RC1 ♦173 556 RECEPTACLE, str 2p3w 32a 130v flange mtg (export models) 1. . . . . . . . . . . . . . . . . . .

RC2 ♦176 355 RECEPTACLE, str 2p3w 16a 220v flange mtg (export models) 1. . . . . . . . . . . . . . . . . . . . . .

RC3 ♦173 555 RECEPTACLE, str 2p3w 16a 130v flange mtg (export models) 1. . . . . . . . . . . . . . . . . . . . . .

16 190 861 LABEL, warning, electric shock and moving parts etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 +215 347 PANEL, gen pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 ♦+215 045 PANEL, gen pwr ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 ♦+215 403 PANEL, gen pwr (European Receptacle) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 ♦+204 258 PANEL, gen pwr (110/220 volt receptacles) (export models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

18 083 030 STUD, brs .250−20 x 1.750 w/hex collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 601 836 NUT, 250−20 .50hex .19h brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 ♦196 073 LABEL, do not switch while welding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 S12 ♦195 825 SWITCH, polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 S12 ♦220491 SWITCH, ac/polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 201 125 PANEL, mtg terminal pwr output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 ♦199 303 PANEL, mtg terminal pwr output ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 735 WASHER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 181 169 SPACER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 186 621 BOOT, generic output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 ♦059 773 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 ♦010 647 PIN, spring cs .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 209 056 COVER, receptacle w/gasket 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 206 795 BOOT, circuit breaker clear hex nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 021 385 BOOT, toggle switch lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 201 045 COVER, receptacle twistlock 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 ♦193 228 METER, Volt Dc 8− 18 Scale 2.250 In Black Face 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 FUEL 192 265 GAUGE, fuel elec switch w/o sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4428 Page 94

Quantity

Item

No.

35 HM 210 424 METER, hour 12-24VDC 2.25dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 TEMP 217 084 GAUGE, coolant temp 0− 300 deg f 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 OIL 217 083 GAUGE, pressure oil 0−100 psi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 V1 ♦164 874 VOLT METER, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 A1 ♦164 873 AMMETER, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 189 161 HANDLE, switch range 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 010 647 PIN, spring CS .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 019 602 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Dia.

Mkgs.

Part

No.

Figure 15-4. Panel, Front w/Components − CC Models (Continued)

197 798 SENDER, Coolant Temp 300 Deg F M16 X 1.5 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 230 SENDER, Pressure Oil 0− 100 Psi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦194 403 ADAPTER, oil pressure sender (Deutz F4L2011) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

024 103 BLANK, snap−in nyl .750 mtg hole black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description

Quantity

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4428 Page 95

 Hardware is common and

not available unless listed.

4

3

5

54

43

55

53

56

52

51

57

58

50

14

26

6

8

7

9

10

11

12

13

15

16

17

18

19

20

21

22

23

24

25

2

1

33

31

30

29

28

27

49

48

47

46

45

32

44

34

42

41

35

36

38

3940

37

Figure 15-5. Panel, Front w/Components − CC/CV Models

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 15-5. Panel, Front w/Components − CC/CV Models (Figure 15-1 Item 104)

1 215 664 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 215 014 PANEL, engine/weld control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦220544 PANEL, engine/weld control ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S3 208278 SWITCH, range/changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 558 HARNESS, range (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC6 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

803 663

Quantity

OM-4428 Page 96