Miller Electric Big Blue 302P, Big Blue 452P User Manual

OM-496 197 761AT

March 2004

Processes

Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) W elding

Air Carbon Arc (CAC-A)
Cutting and Gouging

Descriptio n

Engine Driven Welding Generator



Big Blue 302P



Big Blue 452P

(CE Compliant)

Visit our website at

www.MillerWelds.com

And Non-CE Models

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 catalog sheets. To locate your nearest

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

Mil_Thank 7/03

TABLE OF CONTENTS

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

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

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

1-3. Engine Hazards 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

1-5. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. California Proposition 65 Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-8. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2-3. Dangers existant en relation avec le moteur 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Dangers liés à l’air comprimé 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7 . . . . . .

2-6. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Information sur les champs électromagnétiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Warning Label Definitions (CE Models Only) 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Manufacturer’s Rating Labels For CE Products 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 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4-8. Optional Three-Phase Generator Curves 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator (See Sections 5-2 And 5-3) 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Using Lifting Eye 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Mounting Welding Generator 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Installing Exhaust Pipe 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Activating The Dry Charge Battery (If Applicable) 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Connecting The Battery 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Engine Prestart Checks 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Connecting To Weld Output Terminals 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Selecting Weld Cable Sizes* 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 28 . . . . . . . . . . . . . . . . . . . . .

5-11. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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/Conta c t o r S w i t c h O n C C / C V M o d e l s 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

TABLE OF CONTENTS

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 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − MAINTENANCE & TROUBLESHOOTING 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Maintenance Labels 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Routine Maintenance 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Servicing Air Cleaner 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-5. Adjusting Engine Speed On Standard Models 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-6. Adjusting Engine Speed On Models With Automatic Idle (Optional) 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-7. Servicing Fuel And Lubrication Systems 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-8. Overload Protection 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-9. Diagnosing Causes Of Engine Fault Shutdowns 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-10. Troubleshooting 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − ELECTRICAL DIAGRAMS 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − RUN-IN PROCEDURE 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. Wetstacking 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-2. Run-In Procedure Using Load Bank 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-3. Run-In Procedure Using Resistance Grid 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − GENERATOR POWER GUIDELINES 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − PARTS LIST 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES
WARRANTY

Declaration of Conformity for

European Community (CE) Products

NOTE

Manufacturer’s Name: Miller Electric Mfg. Co.

Manufacturer’s Address: 1635 W. Spencer Street

This information is provided for units with CE certification (see rating label on unit).

Appleton, WI 54914 USA

Declares that the product: Big Blue 452P

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

Machinery Directives: 98/37/EEC,91/368/EEC, 93/C 133/04, 93/68/EEC

Noise level of Welding Generators: 2000/14/EC

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC

Standards

Safety Requirements for Arc Welding Equipment IEC 60974-1: 1998-09

Rotating Electrical Machines − Part 1: Rating and Performance: IEC 34-1: 1994

Rotating Electrical Machines − Part 5: Classification of degrees of protection provided by enclosure of rotating

electrical machines (IP code): IEC 34-5: 1991

Insulation coordination for equipment within low-voltage systems:

Part 1: Principles, requirements and test: IEC 60664-1: 2000-04

Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995

European Contact: Mr. Danilo Fedolfi, Managing Director

ITW WELDING PRODUCTS ITALY S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy

Telephone: [phone]

Fax: [phone]

dec_con1 _11/02

Declaration of Conformity for

European Community (CE) Products

NOTE

Manufacturer’s Name: Miller Electric Mfg. Co.

Manufacturer’s Address: 1635 W. Spencer Street

This information is provided for units with CE certification (see rating label on unit).

Appleton, WI 54914 USA

Declares that the product: Big Blue 452P

conforms to the following Directives and Standards relating to sound levels:

Directives

Noise Level Of Welding Generators: 2000/14/EC

Sound Level Information

Measured Sound Power Level: 98 dB

Guaranteed Sound Power Level: 98 dB

This equipment conforms to requirements brought forth by 2000/14/EC

Noise conformity assessment procedure followed with notified body:

AV Technology Limited

AVTECH House

Birdhall Lane

Cheadle Heath

Stockport

Cheshire
SK3OXU

Sound power level requirements determined by the 40% duty cycle of 500 A, 30 V

Conforming assessment procedure 1 of Annex VI will be followed.

European Contact: Mr. Danilo Fedolfi, Managing Director

MILLER Europe S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy

Telephone: [phone]

Fax: [phone]

dec_con1 5/98

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom _nd_8/03

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

1-1. Symbol Usage

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

 Marks a special safety message.

 Means “Note”; not safety related.

1-2. Arc Welding Hazards

 The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see the
symbol, watch out, and follow the related instructions to avoid the
hazard. The safety information given below is only a summary of
the more complete safety information found in the Safety Stan­dards listed in Section 1-7. Read and follow all Safety Standards.

 Only qualified persons should install, operate, maintain, and re-

pair 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

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 following electri-

cally 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.

 Always verify the supply ground — check and be sure that input power cord

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

 When making input connections, attach proper grounding conductor first −

double-check connections.

 Frequently inspect input power cord for damage or bare wiring — replace

cord immediately if damaged — bare wiring can kill.

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

arate cable.

 Do not touch electrode if you are in contact with the work, ground, or anoth-

er electrode from a different machine.

live whenever the output is on. The input power circuit and

Return To Table Of Contents

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

 Use only well-maintained equipment. Repair or replace damaged parts at

once. Maintain unit according to manual.

 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 work-

table 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.

FUMES AND GASES can be hazardous.

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

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

fumes and gases.

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

instructions for metals, consumables, coatings, cleaners, and degreasers.

 Work in a confined space only if it is well ventilated, or while wearing an air-

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

 Do not weld in locations near degreasing, cleaning, or spraying operations.

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

 Do not weld on coated metals, such as galvanized, lead, or cadmium plated

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

BUILDUP OF GAS can injure or kill.

 Shut off shielding gas supply when not in use.
 Always ventilate confined spaces or use approved

air-supplied respirator.

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 a welding helmet fitted with a proper shade of filter to protect your face

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

 Wear approved safety glasses with side shields under your helmet.
 Use protective screens or barriers to protect others from flash and glare;

warn others not to watch the arc.

 Wear protective clothing made from durable, flame-resistant material (wool

and leather) and foot protection.

OM-496 Page 1

WELDING can cause fire or explosion.

HOT PARTS can cause severe burns.

Welding on closed containers, such as tanks, drums, or
pipes, can cause them to blow up. Sparks can fly off from the

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

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

possible, tightly cover them with approved covers.

 Be alert that welding sparks and hot materials from welding can easily go

through small cracks and openings to adjacent areas.

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

fire on the hidden side.

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

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

 Connect work cable to the work as close to the welding area as practical to

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

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

when not in use.

 Wear oil-free protective garments such as leather gloves, heavy shirt, cuf-

fless trousers, high shoes, and a cap.

 Remove any combustibles, such as a butane lighter or matches, from your

person before doing any welding.

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

work and have a fire watcher and extinguisher nearby.

welding arc. The flying sparks, hot workpiece, and hot

FLYING METAL can injure eyes.

 Welding, chipping, wire brushing, and grinding cause

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

 Wear approved safety glasses with side shields even

under your welding helmet.

 Allow cooling period before maintaining.
 Wear protective gloves and clothing when working on

a hot engine.

 Do not touch hot engine parts or just-welded parts

bare-handed.

NOISE can damage hearing.

Noise from some processes or equipment can damage
hearing.

 Wear approved ear protection if noise level is high.

MAGNETIC FIELDS can affect pacemakers.

 Pacemaker wearers keep away.
 Wearers should consult their doctor before going

near arc welding, gouging, or spot welding opera­tions.

CYLINDERS can explode if damaged.

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

 Protect compressed gas cylinders from excessive heat, mechanical

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

 Install cylinders in an upright position by securing to a stationary support or

cylinder rack to prevent falling or tipping.

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

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

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

connected for use.

 Read and follow instructions on compressed gas cylinders, associated

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

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

 Always wear a face shield, rubber gloves, and protec-

tive clothing when working on a battery.

 Stop engine before disconnecting or connecting bat-

tery 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 add-

ing 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.

OM-496 Page 2 Return To Table Of Contents

 Stop engine before installing or connecting unit.
 Have only qualified people remove guards or covers for maintenance

and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect negative (−)

battery cable from battery.

 Keep hands, hair, loose clothing, and tools away from moving parts.
 Reinstall panels or guards and close doors when servicing is finished

and before starting engine.

 Before working on generator, remove spark plugs or injectors to keep

engine from kicking back or starting.

 Block flywheel so that it will not turn while working on generator compo-

nents.

MOVING PARTS can cause injury.

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

and securely in place.

STEAM AND HO T C OOLANT can burn.

BREATHING COMPRESSED AIR can

.

TRAPPED AIR PRESSURE AND WHIPPING

 If possible, check coolant level when engine is cold to

avoid scalding.

 Always check coolant level at overflow tank, if pres-

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

 If the engine is warm, checking is needed, and there is no overflow tank,

follow the next two statements.

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

moving cap.

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 flam-

mables.

ENGINE EXHAUST GASES can kill.

 Use equipment outside in open, well-ventilated ar-

eas.

 If used in a closed area, vent engine exhaust outside

and away from any building air intakes.

1-4. Compressed Air Hazards

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.

HOSES can cause injury.

 Release air pressure from tools and system before

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

EXHAUST SPARKS can cause fire.

 Do not let engine exhaust sparks cause fire.
 Use approved engine exhaust spark arrestor in re-

quired areas — see applicable codes.

HOT METAL from air arc cutting and
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 servicing.

READ INSTRUCTIONS.

 Read Owner’s Manual before using or servicing unit.
 Stop engine and release air pressure before

servicing.

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

FALLING UNIT can cause injury.

 Use lifting eye to lift unit only, NOT running gear, gas

cylinders, trailer, or any other accessories.

 Use equipment of adequate capacity to lift and

support unit.

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

enough to extend beyond opposite side of unit.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or stop-

ping 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.

 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,

 Sparks can cause fires — keep flammables away.

and body protection.

Return To Table Of Contents

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 accord-

ing to instructions supplied with trailer .

OM-496 Page 3

READ INSTRUCTIONS.

ARC WELDING can cause interference.

 Use only genuine MILLER/Hobart replacement

parts.

 Perform engine and air compressor (if applicable)

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

H.F. RADIATION can cause interference.

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

tion, 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

 W elding 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 electro-

magnetically compatible.

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

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

 Locate welding operation 100 meters from any sensitive electronic

equipment.

 Be sure this welding machine is installed and grounded according to this

manual.

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

moving the welding machine, using shielded cables, using line filters, o r
shielding the work area.

For Gasoline Engines:
 Engine exhaust contains chemicals known to the State of

California t o 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 i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society , 550 N.W. LeJeune Rd, Miami FL 33126
(phone: [phone], website: www.aws.org).

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

AWS F4.1, from American Welding Society , 550 N.W. LeJeune Rd, Mi­ami, FL 33126 (phone: [phone], website: www.aws.org).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (phone: [phone], website: www.nfpa.org and www.
sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: [phone], website:
www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-

1-8. EMF Information

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

Welding current, as it flows through welding cables, will cause electro­magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to 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.

levard, Rexdale, Ontario, Canada M9W 1R3 (phone: [phone] or
in Toronto 416-747-4044, website: www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: [phone],
website: www.ansi.org).

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

P.O. Box 9101, 1 Battery March Park, Quincy , MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.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 (there
are 10 Regional Offices—phone for Region 5, Chicago, is
312-353-2220, website: www.osha.gov).

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

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

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

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

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

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

About Pacemakers:

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

OM-496 Page 4 Return To Table Of Contents

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_fre 8/03

 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.

2-1. Signification des symboles

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

 Identifie un message de sécurité particulier.

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

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 e t suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécu­rité énumérées à la section 2-6 . Veuillez lire et respecter toutes
ces normes de sécurité.

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

doivent être confiés qu’à des personnes qualifiées.

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

particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

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

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

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

de trous.

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

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

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

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

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

procédé de soudage le demande.

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

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

 Des précautions de sécurité supplémentaires sont requises dans des envi-

ronnements 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 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 conformément à son

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

 Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que

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

internes de l’appareil sont également sous tension à ce

Revenez à la table des matières

Ce groupe de symboles si­gnifie Mise en garde !
Soyez vigilant ! Il y a des

aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux
PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-des­sous afin de connaître les mesures à prendre pour éviter tout danger.

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

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

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

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

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

mal épissés.

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

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

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

une électrode provenant d’une autre machine.

 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.

risques de danger reliés

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

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

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

LES FUMÉES ET LES GAZ peuvent
être dangereux.

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

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

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

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

homologué.

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

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

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

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

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

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

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

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

OM-496 Page 5

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

 Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

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

rateur d’adduction d’air homologué.

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

Le rayonnement de l’arc du procédé de soudage génère

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

 Porter un casque de soudage muni d’un écran de filtre approprié pour pro-

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

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

trop élevé.

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

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

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

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

des rayons visibles et invisibles intenses (ultraviolets et

LE SOUDAGE peut provoquer un in­cendie ou une explosion.

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

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

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

chaud.

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

substances inflammables.

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

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

 Des étincelles et des matériaux chauds du soudage peuvent facilement

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

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

clencher un incendie de l’autre côté.

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

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

 Brancher le câble sur la pièce le plus près possible de la zone de soudage

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

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

de ou couper le fil à la pointe de contact.

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

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

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

qu’un allumeur au butane ou des allumettes.

leur éclatement. Des étincelles peuvent être projetées de

 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.

DES PARTICULES VOLANTES
peuvent blesser les yeux.

 Le soudage, l’écaillement, le pa ssage de la pièce

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

lantes. 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.

des étincelles et des particules métalliques vo-

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Prévoir une période de refroidissement avant d’effec-

tuer des travaux d’entretien.

 Porter des gants et des vêtements de protection pour

travailler sur un moteur chaud.

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

récemment soudées.

LE BRUIT peut affecter l’ouïe.

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

 Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.

 Porteurs de stimulateur cardiaque, restez à distance.
 Les porteurs d’un stimulateur cardiaque doivent

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

Si des BOUTEILLES sont endomma­gées, elles pourront exploser.

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

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

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

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

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

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

électriques.

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

teille.

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

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

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

ou de branchement de la bouteille.

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

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

2-3. Dangers existant en relation avec le moteur

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

 Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

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

rateur d’adduction d’air homologué.

OM-496 Page 6

Revenez à la table des matières

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.

L’EXPLOSION DE LA BATTERIE peut

-

r

r

-

RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gants en

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

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

batterie.

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

batterie.

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

cules 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 pro­voquer un incendie ou une explosion.

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

rant ou de faire le plein.

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

ce d’étincelles ou d’une flamme nue.

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

expansion.

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

rant renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.

 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 orga-

nes mobiles.

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

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

 Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise e n

route accidentelle du moteur.

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

générateur.

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

 Il est préférable de vérifier le liquide de

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

 Toujours vérifier le niveau de liquide de refroidissement dans le vase d’ex-

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

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

vant :

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

chon du radiateur.

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

d’enlever le bouchon.

LA CHALEUR DU MOTEUR peut pro­voquer un incendie.

DES ORGANES MOBILES peuvent
provoquer des blessures.

 Ne pas approcher les mains des ventilateurs, cour-

roies et autres pièces en mouvement.

 Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de
protection.

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

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

2-4. Dangers liés à l’air comprimé

RESPIRER L’AIR COMPRIMÉ peut pro
voquer des blessures graves ou cause
la mort.

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

ge, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoque
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 provo
quer des blessures.

 Relâcher l a pression d’air de l’outillage ou du sys-

tème 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.

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

de surfaces inflammables.

 Tenir à distance les produits inflammables de

l’échappement.

LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

 Utiliser uniquement un pare-étincelles approuvé −

voir codes en vigueur.

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

 Ne pas couper ou gouger à proximité de produits

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 élé-

ments 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.

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

maintenance

LA CHUTE DE L’APPAREIL peut
blesser.

 Utiliser l’anneau de levage uniquement pour soulever

l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.

Revenez à la table des matières

 Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

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

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

OM-496 Page 7

LE SURCHAUFFEMENT peut endom­mager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant de dé-

marrer ou d’arrêter le moteur.

 Ne pas laisser tourner le moteur trop lentement sous

risque d’endommager le moteur électrique à cause
d’une tension et d’une fréquence trop faibles.

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

lieu.

LES ÉTINCELLES VOLANTES ris­quent de provoquer des blessures.

 Porter un écran facial pour protéger le visage et les

yeux.

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

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

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

inflammable.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter le facteur de

marche nominal.

 Réduire le courant ou le facteur de marche avant de

poursuivre le soudage.

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

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les
circuits imprimés.

 Établir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques

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

UNE REMORQUE QUI BASCULE peut
entraîner des blessures.

 Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.

 Installer convenablement le poste sur la remorque

comme indiqué dans le manuel s’y rapportant.

LIRE LES INSTRUCTIONS.

 Utiliser seulement les pièces de rechange d’origine.
 Effectuer la maintenance du moteur et du compres-

seur (si applicable) suivant ce manuel et 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 électricien quali-

fié les interférences résultant de l’installation.

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

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

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

 L’énergie électromagnétique risque de provoquer

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

 Veiller à c e que tout l’équipement de la zone de soudage soit compatible

électromagnétiquement.

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

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

 Veiller à s ouder à une distance de 100 mètres de tout équipement élec-

tronique sensible.

 Veiller à c e que ce poste de soudage soit posé et mis à la terre conformé-

ment à ce mode d’emploi.

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

combe à l’utilisateur de prendre des mesures supplémentaires telles qu e
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.

2-6. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (télé­phone : (305) 443−9353, site Web : www.aws.org).
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping, norme American Welding Society AWS F4.1, de
l’American Welding Society, 550 N.W . LeJeune Rd, Miami, FL 33126 (télé­phone : (305) 443−9353, site Web : www.aws.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection As­sociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101
(téléphone : (617) 770−3000, sites W e b : w w w.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de
la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web :
www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Cana­dian Standards Association, Standards Sales, 178 boulevard Rexdale,

Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à To­ronto : (416) 747−4044, site Web : www.csa−international.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site
Web : www.ansi.org).
Standard for F i r e P r e v e n t i o n During Welding, Cutting, and Other Hot Work,
norme NFPA 51B, de la National Fire Protection Association, P.O. Box
9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
770−3000, site Web : www.nfpa.org et www.sparky.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 l’U.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
Web : www.osha.gov).

2-7. Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnétiques
basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électro­magnétiques. Les effets potentiels de tels champs restent préoccupants.
Cependant, après avoir examiné plus de 500 études qui ont été faites pen­dant une période de recherche de 17 ans, un comité de spécialistes du
National Research Council a conclu : « L’accumulation de preuves n’a pas
démontré que l’exposition aux champs magnétiques et aux champs électri­ques à haute fréquence constitue un risque pour la santé humaine ».
Toutefois, les études et l’examen des preuves se poursuivent. En attendant
les conclusions finales de la recherche, il serait souhaitable de réduire l’ex­position aux champs électromagnétiques pendant le soudage ou le
coupage.

OM-496 Page 8

Revenez à la table des matières

Afin de réduire les champs électromagnétiques en milieu de travail, respec­ter les consignes suivantes :

1. Garder les câbles ensemble en les torsadant ou en les fixant avec du

ruban adhésif.

2. Mettre tous les câbles du côté opposé à l’opérateur.

3. Ne pas s’enrouler les câbles autour du corps.

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

5. Placer la pince de masse le plus près possible de la zone de soudage.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom­mandé de respecter les consignes ci-dessus.

SECTION 3 − DEFINITIONS

3-1. Warning Label Definitions (CE Models Only)

Warning! Watch Out! There are
possible hazards as shown by the
symbols.

Become trained and read the
instructions before working on the
machine o r welding.

1 Electric shock from welding

electrode or wiring can kill.

1.1 Wear dry insulating gloves. Do
not touch electrode with bare
hand. Do not wear wet or
damaged gloves.

1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.

1.3 Do not work on unit if engine
is running. Stop engine first.

2 Breathing welding fumes can

be hazardous to your health.

2.1 Keep your head out of the
fumes.

2.2 Use forced ventilation or local
exhaust to remove the fumes.

2.3 Use ventilating fan to remove
fumes.

3 Welding sparks can cause

explosion or fire.

3.1 Keep flammables away from
welding. Do not weld near
flammables.

3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.

3.3 Do not weld on drums or any
closed containers.

4 Arc rays can burn eyes and

injure skin.

4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar . Use welding helmet
with correct shade of filter.
Wear complete body
protection.

5 Do not remove or paint over

(cover) the label.

6 Engine fuel plus flames or

sparks can cause fire.

6.1 Do not smoke while fueling or if
near fuel.

6.2 Stop engine before fueling.

6.3 Do not fuel a hot engine.

7 Engine exhaust gases can kill.

7.1 Vent exhaust outside.

7.2 Use unit outside.

3/96

OM-496 Page 9Return To Table Of Contents

10

11

1

1

−+

2 3 4 5 6

4

4

1

+−

+−

7

2

3

+−

89 12

3

+−

S-176 108

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Do not smoke and keep

matches and flames away from
battery.

3 Sparks can cause battery

gases to explode. Battery
explosion can blind and injure.
Wear a face shield.

4 Battery acid can burn skin. Do

not spill acid.

5 Read Owner’s Manual.
6 Wear rubber gloves.
7 Dead battery
8 Engine block
9 Fully charged battery

2

10 Do not connect last negative

cable to dead battery − connect
instead t o engine block.

11 Jumper cables − observe

polarity and make connections
in numbered sequence shown.

12 Once dead battery is charged,

disconnect cables in sequence
shown.

3/96

1

2

S-176 106

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Moving parts, such as fans,

rotors, and belts, can cut
fingers and hands and cause
injury. Keep away from moving
parts.

3/96

Starting Aid Switch. Below 32°F (0°C),
push switch up for 60 seconds before
starting engine.

Starting Instructions:

1 Press and hold Magnetic

Shutdown switch.

2 Turn Engine Control switch to

Start position.

3 Release Engine Control switch

and Starting Aid switch (if used)
when engine starts.

4 Continue holding Magnetic

Shutdown switch for 3 seconds
after engine starts.

OM-496 Page 10

Return To Table Of Contents

1

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Hot muffler and exhaust pipes

can cause severe burns. Do
not touch hot muffler or pipes.

2

S-176 230

1

1 Warning! Watch Out! There

3/96

are possible hazards as
shown by the symbols.

2

3

2 Engine fuel plus flames or

sparks can cause fire.

3 Do not smoke while fueling or if

near fuel.

4 Stop engine before fueling.

4

5

5 Do not fuel a hot engine.
6 Use Diesel Fuel only.

6

1

2 3 4

3/96

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Falling equipment can cause

serious injury and damage.

3 Use lifting eye to lift or move

unit only. Use proper
equipment when lifting.

4 Do not use lifting eye to lift and

support unit and trailer or other
heavy devices or accessories.

S-176 104

3/96

OM-496 Page 11Return To Table Of Contents

1 Warning! Watch Out! There

are possible hazards as

1

2

5

34

shown by the symbols.

2 Fire hazard from leaking

engine fuel. Fire can result from
welding on base at
non-designated areas causing
a possible fuel leak.

3 Fuel tank is located inside

base.
4 Do not weld on base of unit.
5 Weld only on supplied brackets

or bolt unit down.

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

1

2

3

2 Electric shock from wiring can

kill.

3 Moving parts, such as fans,

rotors, and belts, can cut
fingers and hands and cause
injury. Keep away from moving
parts.

OM-496 Page 12

Return To Table Of Contents

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.

API CD-MIL L 2104D,

CD/SE, CD/SF

3-2. Manufacturer’s Rating Labels For CE Products

CC Models CC/CV Models

3/96

OM-496 Page 13Return To Table Of Contents

3-3. Symbols And Definitions

A

3

Hz

U

U

NOTE

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

Engine

Temperature

Slow (Idle) Start Engine

Engine Oil

Pressure

Fuel

Certified/Trained

Mechanic

Output

Engine Oil

Protective Earth

(Ground)

Welding Arc

Alternating

Current

X

n

Stick (SMAW)

Welding

Time

h

Three Phase

Electrode

Connection

Duty Cycle

Rated Idle

1

Speed n

Contactor On

0

0

Constant Current

(CC)

Hours

Read Operator’s

Manual

Work Connection

Rated No Load

Voltage (A verage)

Rated No Load

Speed

s

G

3

I

MIG (GMAW)

Welding

Seconds

Circuit Breaker

Engine-Driven,

Three-Phase

Alternator With

Rectifier

Conventional

2

Load Voltage

Current

1

n

I

2

TIG (GTAW)

Single Phase

Do Not Switch
While Welding

Hertz

Rated Load

Speed

Rated Welding

Current

OM-496 Page 14

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SECTION 4 − SPECIFICATIONS

Three-Phase Generator

25 gal

400 A, 40 Volts DC,

Three-Phase Generator

,

Perkins 404-22

25 gal

G

Do not move or operate unit where it could

 Do not move or operate unit where it could

B

C

30

30

Front Panel End

30°

Front Panel End

20

E

4-1. Weld, Power, And Engine Specifications

Maximum

Welding

Mode

CC/DC

CV/DC

(CC/CV

Models

Only)

4-2. Dimensions, Weights, And Operating Angles

Height

Width

Depth 65-1/8 i n (1654 mm)

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

E 27-1/2 i n (699 mm)

F 1 in (25 mm)

G 29-1/2 in (743 mm)

H

* With mounting brackets in center

position. Dimensions vary with
location of mounting brackets.

w/ Perkins

104-22

Weld Output

Range

45 − 500 A

(CC Models)

15 − 500 A

(CC/CV Models)

14 − 40 V

Dimensions

60 in (1524 mm)

(to top of muffler)

28-1/2 i n (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: 1600 lb (726 kg)

w/fuel: 1775 lb (805 kg)

Rated Welding

Output

300 A, 40 Volts DC,

100% Duty Cycle

400 A, 40 Volts DC,

60% Duty Cycle

500 A, 30 Volts DC,

40% Duty Cycle

A

D

Open-

Circuit

Voltage

95

56

H

Single-Phase/Three-Phase

12/15 kVA/kW, 50/36A,

*In Addition To Standard

4 kVA/kW Generator Power

G

Generator Power

Rating

Standard

Single-Phase,

4 kVA/kW, 34/17 A,

120/240 V AC,

50/60 Hz

Option*

120/240 VAC, 60 Hz

 Do not exceed tilt angles or engine could

be damaged or unit could tip.



tip.

20°
20°

F

802 161-A

Engine

Perkins

Water-Cooled,
Four-Cylinder,

32.8 HP Diesel Engine

Fuel

Capacity

(95 L)

°

°

OM-496 Page 15Return To Table Of Contents

4-3. Volt-Ampere Curves For CC Models

100

80

60

40

DC VOLTS

20

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

Ranges

210 − Max

165 − 350
100 − 250

65 − 120
45 − 85

0

0 100 200 300 400 500 600 700

DC AMPERES

202 666-A

OM-496 Page 16

Return To Table Of Contents

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

B. MIG Mode

100

80

DC AMPERES

Ranges

Max

150 − 420

110 − 315

75 − 200
40 − 90

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

60

40

DC VOLTS

20

0

0 100 200 300 400 500 600 700 800 900 1000

C. TIG Mode

100

90
80
70
60
50
40

DC VOLTS

30
20
10

0

0 50 100 150 200 250 300 350 400 450 500

MIN

MAX

DC AMPERES

DC AMPERES

Ranges
50 − 335
40 − 240

25 − 150
15 − 75

202 655 / 202 656 / 202 654

OM-496 Page 17Return To Table Of Contents

4-5. Fuel Consumption

2.00

1.75

1.50

1.25

1.00

US GAL/HR.

0.75

0.50

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

0.25

IDLE

0.00
0 50 100 150 200 250 300 350 400

DC WELD AMPERES AT 100% DUTY CYCLE

4-6. Duty Cycle And Overheating

100% Duty Cycle At 300 Amperes

Continuous Welding

199 032

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

 Exceeding duty cycle can

damage unit and void
warranty.

WELD AMPERES

OM-496 Page 18

% DUTY CYCLE

199 140

Return To Table Of Contents

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

0102030405060

AC AMPERES IN 120V MODE

4-8. Optional Three-Phase Generator Curves

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

193 018

A. 12 kVA/kW Single-Phase AC Output (No Weld Load)

280

260

240

220

AC VOLTS

200

180

0 20 40 60 80 100

AC AMPERES

B. 15 kVA/kW Three-Phase AC Output (No Weld Load)

280

260

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.

AC VOLTS

240

220

200

180

0 10203040506070

AC AMPERES

198 868 / 198 869

OM-496 Page 19Return To Table Of Contents

SECTION 5 − INSTALLATION

5-1. Installing Welding Generator (See Sections 5-2 And 5-3)

Movement

OR OR

Location

OR

OR

 Always securely fasten weld-

ing generator onto transport
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.

 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 A WG or larger insu­lated copper wire.

Grounding

GND/PE

Airflow Clearance

1

2

18 in

(460 mm)

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

3

 Bed liners, shipping skids, and some running

gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding termi­nal to bare metal on the vehicle frame as shown.

18 in

(460 mm)

18 in

(460 mm)

OM-496 Page 20

18 in

(460 mm)

18 in

(460 mm)

install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274

Return To Table Of Contents

5-2. Using Lifting Eye

1 Lifting E y e
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:

Ref. 802 311

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-496 Page 21Return To Table Of Contents

5-3. Mounting Welding Generator

Supporting The Unit

Inadequate support.

 Do not use flexible mounts.

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.

 Do not mount unit by sup-

porting the base only at the
four mounting brackets.
Use cross-supports to ade-

2

OR

1

1

2

quately 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 t o the base.
Reverse brackets and reattach to
base with original hardware.

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

To Weld Unit In Place:

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

Tools Needed:

OM-496 Page 22

Welding Unit In Place

Bolting Unit In Place

3

2

4

9/16 in

install3 5/02 803 274 / 190 250-A / 803 231 / 802 311

Return To Table Of Contents

5-4. Installing Exhaust Pipe

 Stop engine and let cool.

 Point exhaust pipe in desired di-

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

Tools Needed:

1/2 in

Notes

Ref. 802 311 / Ref. 201 841

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-496 Page 23Return To Table Of Contents

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

4

1

3

2

Remove battery from unit.
1 Eye Protection − Safety

Glasses Or Face Shield

2 Rubber Gloves

5

3 Vent Caps
4 Sulfuric Acid Electrolyte

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

bottom of well (maximum).

 Do not overfill battery cells.

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

6 Battery Charger

 Read and follow all instruc-

tions supplied with battery

charger.

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

 When electrolyte is low, add

only distilled water to cells to

maintain proper level.

5 A For 30 Minutes

30 A For 12 Minutes

OM-496 Page 24

OR

6

Tools Needed:

+

−

Return To Table Of Contents

rubber gloves

glasses

drybatt1 1/98 − 0886

5-6. Connecting The Battery

Tools Needed:

y.

Notes

1/2 in

 Reinstall cover after connecting batter

 Connect Negative (−) Cable Last.

+

−

802 168-B / Ref. 201 841 / 802 313 / S-0756-C

OM-496 Page 25Return To Table Of Contents

5-7. Engine Prestart Checks

Check radiator coolant

level when fluid is low in

recovery tank.

Full

Diesel

104.22 Engine: 9.5 qt (9.01L)

Capacity:

Full

Full

Coolant Recovery Tank

Hot Full

 Check all engine fluids daily.

Engine must be cold and on a level surface.
Unit is shipped with 20W break-in oil.

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 11.

Fuel
 Do not use gasoline. Gasoline will

damage engine.

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

OM-496 Page 26

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

Oil

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

Coolant

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

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

Unit is shipped with an engine coolant mix­ture of water and ethylene glycol base anti-

freeze rated to −34° F (−37° C). Add anti-

Return To Table Of Contents

Cold Full

802 490

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

Keep radiator and air intake clean and free
of dirt.

 Incorrect engine temperature can

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

 To improve cold weather starting:

Use Starting Aid switch (see Section
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).

5-8. Connecting To Weld Output Terminals

1

2

802 311

Tools Needed:

3/4 in

 Stop engine.

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

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 P o l a r i t y / A C s w i t c h , connect wire feeder
cable to Electrode (+) terminal on left and
work cable to Work (−) terminal on right.

5-9. Selecting Weld Cable Sizes*

100 ft (30 m) or Less

Weld Output

Terminals

 Stop engine before

connecting t o 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)

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)

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

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

400 ft

(120 m)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

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 cables overheat (normally you can smell it), use next size larger cable.

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

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

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

OM-496 Page 27Return To Table Of Contents

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models

1 Remote Amperage Adjust

Receptacle RC13
Connect optional remote control to

RC13 (see Section 6-3).

1

Notes

Ref. 154 862-A / 048 720-K / 802 311

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-496 Page 28

Return To Table Of Contents

5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models

24 VOLTS AC

24 VOLTS AC

distance remote

OUTPUT

distance remote

OUTPUT

Notes

Socket* Socket Information

A 24 volts ac. Protected by circuit

B Contact closure to A completes

C Output to remote control:+10

breaker 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

(includes 120 V

receptacle)

*The remaining sockets are not used.

OR

802 311

REMOTE

CONTROL

115 VOLTS AC

GND

NEUTRAL G Circuit common for 24 and 115

D Remote control circuit common.

E DC input command signal: 0 to

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

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

I

CB6.

Contact closure to I completes
115 volt ac contactor control

J

circuit.

K Chassis common.

volt ac circuit.

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-496 Page 29Return To Table Of Contents

SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS

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

65

13 18 1914 1210 11

47

9

8

2

OM-496 Page 30

17

15 16

Return To Table Of Contents

3

1

201 841 / 802 311

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

Engine Starting Controls

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

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

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

weather starting (see starting instructions fol­lowing).

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

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

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

To Start:

 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 while pressing Shutdown
switch. Release Engine Control switch when
engine starts. Continue holding Shutdown
switch until engine indicator lights go out.

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

To Stop: turn Engine Control switch to Off
position.

Engine Indicator Lights

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

ing battery. Engine continues to run.

 Stop engine and fix trouble if Battery

Charging light goes on.

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

perature is above 221 ° F (105° C).

 Stop engine and fix trouble if Engine

Temperature light goes on.

6 Engine Oil Pressure Light

Light goes on and engine stops if oil pressure
is below 5 psi (34 kPa). Light goes on momen­tarily during start-up but goes out when en­gine reaches normal oil pressure.

 Stop engine and fix trouble if Engine

Oil Pressure light stays on after start­up.

7 Fuel Light
Light is not active on this model.
8 Engine Hour Meter

Engine Gauges

 To read gauges and engine indicator

lights with engine off, turn Engine Control
switch to Run/Idle and press Magnetic
Shutdown switch (see Section 9-9).

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

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

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

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

11 Engine Coolant T emperature Gauge

(Optional)

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

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

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

Weld Controls

 Max OCV Control Circuit: This unit has

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

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

13 Ampere Range Switch

 Do not switch under load.

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

14 Amperage Adjust Control
Control adjusts amperage within range se-

lected by Ampere Range switch. Weld output
would be about 153 A DC with controls set as
shown (50% of 100 to 205 A).

 The numbers around the control are for

reference only and do not represent an
actual percentage value.

15 Stick/TIG Selection Switch
Use switch to disable 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.

16 Amperage Adjust Switch And Remote

Amperage Adjust Receptacle

Connect optional remote control to RC13
(See Section 5-10). Use switch to select front
panel or remote amperage control. For re­mote control, place switch in Remote position
and connect remote control to Remote Am­perage Adjust receptacle RC13 (see Sec­tions 5-10 and 6-3).

17 Polarity Switch (Optional)

 Do not switch under load.

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

Weld Meters

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

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

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

unit.

OM-496 Page 31Return To Table Of Contents

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

6-4. Weld Control/Arc Condition Information Label

1

1 Remote Amperage Adjust

Receptacle RC13
Connect optional remote control to

RC13 (see Section 5-10).

Example: Combination Remote Amperage Control (Stick)

In Example:

Range = 100 to 205 A DC

Percentage Of Range = 50%

Max = About 153 A DC (50% of 100 to 205)

Max (153 A DC)

Min (75 A DC)

Adjust Optional Remote ControlSet Switches Set Range Set Control

Ref. 154 862-A / Ref. 181 711-A / 802 311

 Set weld controls as shown to

achieve softer or stiffer arc condi­tions for different applications.

OM-496 Page 32

212 944-A

Return To Table Of Contents

Notes

OM-496 Page 33Return To Table Of Contents

SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS

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

65

14 19 2015 1210 11

47

9

8

2

OM-496 Page 34

18

OR

13

17

Return To Table Of Contents

16

3

1

201 579 / 802 311-D

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

Engine Starting Controls

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

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

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

weather starting (see starting instructions fol­lowing).

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

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

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

To Start:

 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 while pressing Shutdown
switch. Release Engine Control switch when
engine starts. Continue holding Shutdown
switch until engine indicator lights go out.

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

To Stop: turn Engine Control switch to Off
position.

Engine Indicator Lights

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

ing battery. Engine continues to run.

 Stop engine and fix trouble if Battery

Charging light goes on.

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

perature is above 221 ° F (105° C).

 Stop engine and fix trouble if Engine

Temperature light goes on.

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

is below 5 psi (34 kPa). Light goes on momen­tarily during start-up but goes out when en­gine reaches normal oil pressure.

 Stop engine and fix trouble if Engine

Oil Pressure light stays on after start­up.

7 Fuel Light
Light is not active on this model.
8 Engine Hour Meter

Engine Gauges

 To read gauges and engine indicator

lights with engine off, turn Engine Control
switch to Run/Idle and press Magnetic
Shutdown switch (see Section 9-9).

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

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

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

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

11 Engine Coolant T emperature Gauge

(Optional)

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

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

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

Weld Controls

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

switch information.
14 Ampere Range Switch

 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.

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

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

Weld output would be about 213 A DC with
controls set as shown (50% of 110 to 315 A).

 The numbers around the control are for

reference only and do not represent an
actual percentage value.

16 Voltage/Amperage Adjust Switch And

Remote 14 Receptacle

Use switch to select front panel or remote
voltage/amperage control. For remote con­trol, place switch in Remote position and con­nect remote control to Remote 14 receptacle
RC14 (see Sections 5-11 and 7-4).

17 Polarity Switch (Optional)

 Do not switch under load.

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

18 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 ONL Y if required for the

welding process. If AC output is re­quired, use remote output control if
present on unit.

 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

 Optional weld meters do not work with

optional Polarity/AC switch in AC
position.

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

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

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

unit.

OM-496 Page 35Return To Table Of Contents

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

Switch Setting

Process

Output On/Off Control

Engine Auto Idle (Optional)

1 Process/Contactor Switch

 W eld output terminals are ener-

gized when Process/Contactor

1

switch is in an Electrode Hot
position and the engine is run­ning.

 DC voltage is still present at the

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

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

Place switch in Remote positions to
turn weld output on and off with a de­vice con n e cted to the remote 14 recep­tacle.

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

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

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” elect r o d e s .

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

 Place switch in Electrode Hot -

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

 The engine auto idle option does

not work in the Remote-TIG mode.

Process/Contactor Switch Settings

Remote − TIG

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

Remote − MIG MIG (GMAW) At Remote 14 Receptacle Active

Electrode Hot − MIG MIG (GMAW) Electrode Hot Active

Electrode Hot − Stick

Electrode Hot − Scratch

Start TIG

GTA W With HF Unit, Pulsing

Device, Or Remote Control

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting

And Gouging

Scratch Start TIG (GTAW) Electrode Hot Active

At Remote 14 Receptacle Not Active

Electrode Hot Active

OM-496 Page 36

Return To Table Of Contents

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

1

1 Remote 14 Receptacle RC14
Connect optional remote control to

RC14 (see Section 5-11).

Example: Combination Remote Amperage Control (Stick)

Set V/A

Adjust Switch

Example: Combination Remote Amperage Control (TIG)

Set Remote

Process

Set Range Control Not

Used In Remote

Stick Mode

Process = Stick (Using Remote On/Off)

In Example:

Range = 110 to 315 A DC

Min = 110 A DC

Max = 315 A DC

Max (315 A DC)

Min (110 A DC)

Adjust Optional Remote Control

In Example:

Process = TIG (Using Remote On/Off)

Range = 40 to 240 A DC

Percentage Of Range = 50%

Min = 40 A DC

Max = About 140 A DC (50% of 40 to 240)

Set V/A

Adjust Switch

Set Remote

Process

Set Range Set Control

Max (140 A DC)

Min (40 A DC)

Adjust Optional Remote Control

0774 / Ref. 201 579 / 802 169-E

OM-496 Page 37Return To Table Of Contents

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 onc e a m on t h , r u n e n -

gine at weld/power speed and

press test button to verify GFCI

is working properly.

3 Circuit Breaker CB1
4 Circuit Breaker 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 breaker.

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

 If a circuit breaker continues t o

open, contact Factory Autho-

rized 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-496 Page 38

191 624-A

Return To Table Of Contents

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

 Place Process/Contactor switch

Single-Phase Power Connection

Three-Phase Power Connection

Remove plug
before inserting
leads. Reinstall
bushing.

5

6

7

9

8

 Close panel opening

120V

12

if no connections are
made to generator.

Rear Of Panel

91 92 93

240V

120V

240V

240V

1-Phase

240V

3-Phase

AC

Output

Volts

Amps

KVA/KW

Engine Speed 1850 RPM

Lead 42 connects to GROUND stud on
front of unit.

Jumper 42 i s connected to 90 at factory.

Single
Phase

1

120/240

50
12

Three

Phase

3

240

36
15

60 HzFrequency

4

3

2
12

10

11

 Close panel

opening if no
connections
are made to
generator.

Tools Needed:

Single-Phase Generator Power

1 120/240 V 50 A Receptacle

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 Circuit Breaker CB7
Circuit breaker CB7 protects single-

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

Three-Phase Generator Power

 Stop engine.
 Power and weld outputs are

 Have qualified person install ac-

Remove generator power panel
mounting screws. Tilt panel forward.

93

3 Lead 93
4 Lead 92

91

5 Lead 91
6 Lead 42 (Circuit Grounding

90

92

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

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

Lead 42 connects to front panel
Ground stud.

11 User-Supplied Leads
12 Circuit Breaker CB7 User

Connect user-supplied leads to ter­minals on CB7 and to the isolated
neutral terminal and grounding termi­nal as necessary.

 Circuit breaker CB7 protects

Reinstall generator power panel.

in Electrode Hot - Stick position
when using three-phase genera­tor (see Section 7-3).

RC5

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

cording to circuit diagram and
Generator Power Guidelines
(see Section 12).

Lead)

Terminals

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

Ref. 197 399 / 802 332-E

OM-496 Page 39Return To Table Of Contents

8-3. Optional Generator Power Receptacles

European Receptacle

5

6

Australian Receptacle

5

6

South African Receptacle

5

6

1

1 120 V 20 A AC GFCI

Receptacle GFCI1
2 240 V 16 A AC European

Receptacle RC1

2

3 240 V 15 A AC Australian

Receptacle RC1
4 240 V 15 A AC South African

Receptacle RC1
Receptacles supply 60 Hz single-

phase 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 onc e a m on t h , r u n e n -

gine at weld/power speed and

press test button to verify GFCI

is working properly.

31

5 Circuit Breaker CB2
6 Circuit Breaker CB3
CB2 protects GFCI1 from overload.

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

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

 If a circuit breaker continues t o

open, contact Factory Autho-

rized Service Agent.

 Generator power is not af-

fected by weld output.

Maximum output is 2.4 kVA/kW

41

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-496 Page 40

191 624

Return To Table Of Contents

SECTION 9 − MAINTENANCE & TROUBLESHOOTING

9-1. Maintenance Labels

For Non-CE Products For CE Products Only

OM-496 Page 41Return To Table Of Contents

9-2. Routine Maintenance

Note

Note

The engine oil/filter and fuel injector maintenance intervals are different for the Perkins

404.22 and 3.152 engines (see maintenance schedule following).

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

 Stop engine before maintaining.

Recycle engine

fluids.

 See Engine Manual and Maintenance

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

* To be done by Factory Authorized

Service Agent.

Every 8 h

Wipe

Up

Spills.

Coolant

Full

OIL
Full

Check Fluid
Levels. See
Section 5-7.

FUEL

WATER

Drain Water

From Fuel

System.

Every 50 h

Clean Air Filter.

See Section 9-3.

Check air cleaner
hoses for cracks
and loose clamps.

Change Oil. See

Section 9-7.

Replace

Unreadable

Labels.

Clean And

Tighten

Weld

Terminals.

Every 100 h

Clean An d

Tighten
Battery

Connections.

Every 250 h

Change Oil Filter.

See Section 9-7.

Check And

Clean Spark

Arrestor. See

Section 9-4.

OM-496 Page 42

1/2 in.

(13 mm)

Check Belt

Tension.

Every 500 h

Repair Or

Replace

Damaged

Cables.

Return To Table Of Contents

Every 1000 h

Notes

OR

Blow Out Or

Vacuum Inside.

During Heavy

Service,

Clean Monthly.

Change Fuel

Filters. See

Section 9-7.

Check Radiator
Fluid Level. See

Section 5-7.

SLUDGE

Every 2000 h

Clean/Set Injectors.*

FUEL

Drain Sludge

From Fuel
Tank. See

Section 9-7.

Service Welding

Generator Brushes And

Slip Rings. Service More

Often In Dirty Conditions.*

Clearance.*

Check

Valve

MATERIAL THICKNESS REFERENCE CHART

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

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

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

OM-496 Page 43Return To Table Of Contents

9-3. Servicing Air Cleaner

Keep nozzle

2 in (51 mm)

from element.

2

Optional

Blow Inspect

 Stop engine.
 Do not run engine without air

41 3

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.

 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 i t has holes or damaged gaskets.

Reinstall primary element and cap (dust
ejector down).

OM-496 Page 44

aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 201 841

Return To Table Of Contents

9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler

3

 Stop engine and let cool.

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

covering cleanout hole.
3 Exhaust Pipe
Start engine and run at idle speed to

blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.

 Stop engine and let cool.

Reinstall cleanout plug.

2

1

Tools Needed:

3/8 in

Ref. 802 311 / Ref. 802 160 / Ref. 201 841

OM-496 Page 45Return To Table Of Contents

9-5. Adjusting Engine Speed On Standard Models

Engine Speed

(No Load)

Weld/Power

RPM (Hz)

1850 (61.7)

Maximum

3

 Stop engine and let cool.

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

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

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

Contactor switch to Stick − Elec­trode Hot position.

1 Lock Nut
2 Adjustment Screw
Loosen nut. Turn screw until engine

runs at weld/power speed. Tighten
nut.

 Do not set engine speed higher

than specified.

3 Engine Stop Lever
Use lever to stop engine if Engine

Control switch does not work.

 Stop engine.

Close door.

2

1

OM-496 Page 46

Tools Needed:

10 mm

802 490-D / 802 491

Return To Table Of Contents

9-6. Adjusting Engine Speed On Models With Automatic Idle (Optional)

Engine Speed

(No Load)

1850 rpm max
(61.6 Hz)

1250 rpm
(41.6 Hz)

After tuning engine, check engine
speed with tachometer or frequency
meter. See table for proper no load
speed. If necessary, adjust speed
as follows:

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

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

Contactor switch to Stick − Elec­trode Hot position.

Idle Speed Adjustment

1 Throttle Rod/Plunger
2 Locknut
Loosen locknut. Place Engine Con-

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

engine runs at idle speed. Tighten
locknut.

 Be sure solenoid plunger pulls

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

 If necessary, move linkage to

other hole in bracket or move
cotter pin to other hole in throttle
arm to set idle speed correctly.

Weld/Power Speed Adjustment

3 Engine Weld/Power Speed

Adjustment Screw

3

4 Locknut
Place Engine Control switch in Run

position.
Loosen locknut. Turn screw until en-

gine runs at weld/power speed.
Tighten locknut.

 Do not set engine speed higher

than specified.

 Stop engine.

4

If necessary, move
linkage to other hole in
bracket or move cotter
pin to other hole in
throttle arm to set idle
speed correctly.

2

1

802 490 / 802 538-A

OM-496 Page 47Return To Table Of Contents

9-7. Servicing Fuel And Lubrication Systems

4

5

6

3

8

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

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

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

5 Primary Fuel Filter (Fuel/

Water Separator)
6 Petcock
7 Secondary Fuel Filter
8 Fuel Tank Sludge Drain Valve

To change oil and filter:

Route oil drain hose and valve

1

7

2

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

To drain water from fuel system:

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

To replace primary fuel filter:

Turn filter counterclockwise. Re­move filter.

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

Inspect fuel lines, and replace if
cracked or worn.

To replace secondary fuel filter:

See engine manual.

To drain sludge from fuel tank:
 Beware of fire. Do not smoke

and keep sparks and flames

away from drained fuel. Dis-

pose of drained fuel in an en -

vironmentally-safe manner.

Do not leave unit unattended

while drain i n g f u e l t a n k .
 Properly lift unit and secure

in a level position. Use ade-

quate blocks or stands to

support unit while draining

fuel tank.

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

Close door.

OM-496 Page 48

Tools Needed:

802 490 / Ref. 801 434

Return To Table Of Contents

9-8. Overload Protection

 Stop engine.

 When a circuit breaker or fuse

opens, i t 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 kV A/kW
generator power is still available.

21

9

8

7

5

4

3 Circuit Breaker CB4 (Not

Shown)

4 Circuit Breaker CB5

(CC/CV Models Only)

5 Circuit Breaker CB6

(CC/CV Models Only)

6 Circuit Breaker CB10 (Not

Shown)
7 Circuit Breaker CB11
8 Circuit Breaker CB12
9 Circuit Breaker CB13
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
three-phase 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 engine wiring har­ness. On CC models, if CB11 opens
the max OCV circuit does not work
and open circuit voltage is variable at
all times (see max OCV note under
Weld Controls in Section 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 shutdown
circuit. If CB13 opens, the engine
cranks but does not st a r t .

Press button to reset breaker.

802 170-D / Ref. 802 311

OM-496 Page 49Return To Table Of Contents

9-9. Diagnosing Causes Of Engine Fault Shutdowns

Pre-Start Diagnostic Checks

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

 Correct the cause of the shut-

down before operating the
welding generator.

 This unit does not have a bat-

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

Turn Engine Control Switch To Run/Idle

Position While Pressing Magnetic

Shutdown Switch.

Diagnostic Checks While Running

Normal Condition:

Oil Pressure Light On;

Battery Charging And Temperature Lights Off.

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

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

Check Alternator.

If Temperature Light Is On, Correct Cause Of Overheating

(See Engine Manual).

If Engine Is Okay, See Factory Authorized Service Agent.

20s

Start Engine (With No Load Applied).

OM-496 Page 50

Continue Pressing Shutdown Switch

Until Engine Lights Go Off.

Return To Table Of Contents

Engine Lights Go Off As Engine Reaches

Normal Condition:

Normal Operating Condition.

Lights That Stay On After 20 Sec. Indicate Fault

Condition.

Stop Engine And Correct Fault (See Above) If Fault

Continues, See Factory Authorized Service Agent.

Ref. 201 841

9-10. 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 5-10 and 6-1).
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-10).
Check fuse F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check inte-

grated 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 F 1 a n d F 2 , a n d r e p l a c e i f o p e n ( s e e S e c t i o n 9-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (see Section 9-8).
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 F 1 a n d F 2 , a n d r e p l a c e i f o p e n ( s e e S e c t i o n 9-8). 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 correct position.

Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8).
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 5-10).
Reset circuit breaker CB11 (see Section 9-8). Have Factory Authorized Service Agent check control relay

CR7.
Repair or replace remote control device.
Have Factory Authorized Service Agent check OCV control circuit.

OM-496 Page 51Return To Table Of Contents

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 Electrode Hot position, or place switch in a Remot e position and
connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-11 and 7-1).

Check position of Ampere Range switch.
Check position of optional Polarity switch or Polarity/AC switch.
Reset circuit breaker CB11 (see Section 9-8).

Reset circuit breaker CB5 (see Section 9-8). Check for faulty remote device connected to RC14.
Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).

Have Factory Authorized Service Agent check connector board PC6 and connections.
Check fuse F2, and replace if open (see Section 9-8). 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 F 1 a n d F 2 , a n d r e p l a c e i f o p e n ( s e e S e c t i o n 9-8). 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.

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

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

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.

Constant speed wire feeder does not
work.

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

Check fuses F 1 a n d F 2 , a n d r e p l a c e i f o p e n ( s e e S e c t i o n 9-8). 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).
Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.

Place Voltage/Amperage Adjust switch in Remote position.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).
Repair or replace remote control device.
Reset circuit breaker CB5 or CB6 (see Section 9-8).

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).
Repair or replace wire feeder.

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

OM-496 Page 52

Return To Table Of Contents

Trouble Remedy

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 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 circuit breakers.

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

Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (CC models) or field
current regulator board PC1 (CC/CV models) (see Section 9-8).

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). 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 Electrode Hot - Stick position (see Section 7-3).

Reset circuit breaker CB7(see Section 8-2).
Reset circuit breaker CB5 (see Section 9-8).

Check engine weld/power speed, and adjust if necessary (see Section 9-5).
Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board

PC1.

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

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

Check engine weld/power speed, and adjust if necessary (see Section 9-5).

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

Have Factory Authorized Service Agent check engine wiring harness and components.
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check Engine Control switch S1.

OM-496 Page 53Return To Table Of Contents

Trouble Remedy

Engine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine.

Check fuel level.
Reset circuit breaker CB13 (see Section 9-8). Have Factory Authorized Service Agent check engine-

wiring harness and components.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check control relay CR2, and fuel solenoid FS1.

Air in fuel system. See engine manual.

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

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

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

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

Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Sections 5-7 and 9-9).

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).

temperature is too high (see Sections 5-7 and 9-9).
See engine manual.

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).

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

Check fuel level.

Check engine air and fuel filters (see Sections 9-3 and 9-7).
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-TIG.
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 11).

OM-496 Page 54

Return To Table Of Contents

Notes

Return To Table Of Contents

OM-496 Page 55

SECTION 10 − ELECTRICAL DIAGRAMS

OM-496 Page 56

Figure 10-1. Circuit Diagram For CC Welding Generator

Return To Table Of Contents

215 296-B

Return To Table Of Contents

OM-496 Page 57

OM-496 Page 58

Figure 10-2. Circuit Diagram For CC/CV Welding Generator

Return To Table Of Contents

Return To Table Of Contents

215 297-B

OM-496 Page 59

1

11-1. Wetstacking

1

SECTION 11 − RUN-IN PROCEDURE

 Do not perform run-in

procedure at less than 20
volts weld output and do n ot
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.

 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 8/0

OM-496 Page 60

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11-2. 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.

 Do not perform run-in

procedure at less than 20

1

volts weld output and do n ot
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.

 Check oil level frequently dur-

ing run-in; add oil if needed.

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

 Stop engine and let cool.

4 Engine Exhaust Pipe
Repeat procedure if wetstacking is

present.

S-0683

OM-496 Page 61Return To Table Of Contents

11-3. 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.

 Do not perform run-in

procedure at less than 20
volts weld output and do n ot
exceed duty cycle or equip­ment damage may occur.

1 Resistance Grid
Use grid sized for generator rated

output.

1

Turn Off grid.
2 Welding Generator

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

3 Weld Cables
Connect grid to generator weld

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

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

shown, if not provided on generator.
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.

 Check oil level frequently dur-

ing run-in; add oil if needed.

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

 Stop engine and let cool.

6 Engine Exhaust Pipe
Repeat procedure if wetstacking is

present.

OM-496 Page 62

S-0684

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SECTION 12 − GENERATOR POWER GUIDELINES

s

-

-

1

NOTE

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

12-1. Selecting Equipment

1

1 Generator Power Receptacle

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

 Do not use 2-prong plug un

less equipment is double in
sulated.

2

3

OR

Be sure equipment
has this symbol
and/or wording.

gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577

2-2. Grounding Generator To Truck Or Trailer Frame

 Always ground generator

frame t o vehicle frame to pre-

1

GND/PE

2

3

vent electric shock and static
electricity hazards.

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.

 If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

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

 Bed liners, shipping skids, and some running

gear in s u late the welding generator from the v e­hicle frame. Always connect a ground wire from
the generator equipment grounding terminal to
bare metal on the vehicle frame as shown.

Return To Table Of Contents

S-0854

OM-496 Page 63

12-3. Grounding When Supplying Building Systems

1 2

GND/PE

Use ground device as stated

2

3

in electrical codes.

1 Equipment Grounding

Terminal
2 Grounding Cable
Use #10 AWG or larger insulated

copper wire.
3 Ground Device

 Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

12-4. How Much Power Does Equipment Require?

3

2

1

3

AMPERES x VOLTS = WATTS

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

requirement in watts.

4.5 A x 115 V = 520 W

The load applied by the drill is 520 watts.

VOLTS 115
AMPS
Hz

4.5
60

ST-800 576-B

1 Resistive Load
A light bulb is a resistive load and

requires a constant amount of power.
2 Non-Resistive Load
Equipment with a motor is a non-re-

sistive load and requires approxi­mately six times more power while
starting the motor than when running
(see Section 12-8).

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

OM-496 Page 64

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

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

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

S-0623

Return To Table Of Contents

12-5. 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

12-6. 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

Return To Table Of Contents

OM-496 Page 65

12-7. 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-496 Page 66

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12-8. Power Required To Start Motor

4
1

VOLTS AMPS

3

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GHJKLMNP

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

kVA/HP x HP x 1000

VOLTS

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

HP motor with a motor start code of M.

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

11.2 x 1/4 x 1000
230

= 12.2 A

CODE 60

HP

Starting the motor requires 12.2 amperes.

AC MOTOR

230 2.5

M

1/4

= STARTING AMPERAGE

Hz
PHASE

1

2

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

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

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

age (see example).
Welding generator amperage out-

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

S-0624

12-9. 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.

Return To Table Of Contents

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

OM-496 Page 67

12-10.Typical Connections To Supply Standby Power

 Properly install and ground this equipment according to

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

1234

Utility

Electrical

Service

Transfer Switch

5

Essential

Loads

Fused

Disconnect

Switch

(If Required)

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 re-

quired if generator will supply standby
power during emergencies or power out­ages.

1 Utility Electrical Service
2 Transfer Switch (Double-Throw)

Notes

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 (customer-supplied).
Switch rating must be same as or greater
than the branch overcurrent protection.

3 Fused Disconnect Switch
Install correct switch (customer-supplied) if

required by electrical code.
4 Welding Generator Output
Generator output voltage and wiring 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 produ c e enough output to meet all
requirements, connect only essential loads
(pumps, freezers, heaters, etc. − See Sec­tion 12-4).

OM-496 Page 68

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

Return To Table Of Contents

12-11.Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 V olt Loads
 If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

Current

(Amperes)

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

7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)
10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)
15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)
20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)
25 3000 175 (53) 112 (34) 62 (19) 37 (11)
30 3600 150 (46) 87 (26) 50 (15) 37 (11)
35 4200 125 (38) 75 (23) 50 (15)
40 4800 112 (34) 62 (19) 37 (11)
45 5400 100 (30) 62 (19)
50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads
 If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Load (Watts) 4 6 8 10 12 14

Current

(Amperes)

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

7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)
10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)
15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)
20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)
25 6000 350 (107) 225 (69) 125 (38) 75 (23)
30 7000 300 (91) 175 (53) 100 (31) 75 (23)
35 8400 250 (76) 150 (46) 100 (31)
40 9600 225 (69) 125 (38) 75 (23)
45 10,800 200 (61) 125 (38)
50 12,000 175 (53) 100 (31)

*Conductor size is based on maximum 2% voltage drop

Load (Watts) 4 6 8 10 12 14

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

Return To Table Of Contents

OM-496 Page 69

 Hardware is common and

not available unless listed.

SECTION 13 − PARTS LIST

1

116 (CV)

2

117 (CV)

21

19

22

23

24

25

26

18

17

3

14

13

15

12

4

5 6

8

7

11

9

10

16

20

119

112

113

111 (FIG. 13-4 OR 13-5)

110

114

115 (FIG 13-7)

107 (CC ONLY)

109

12

105

106 (FIG 13-2 OR 13-3)
108

98

97

104

103

102

101

100

99

OM-496 Page 70

Figure 13-1. Main Assembly

Return To Table Of Contents

27

28

29

30

32

31

33

35

36

34

37

39

40

43

44

45

46

47

50

51

49

52

48

118

87

88

89

90

97

85 (Fig. 13-6)

86

91

92

93

94

96

95

84

83

38

82

41

81

73

80

72

79

54

74

75

78

71

76
77

60

58

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Figure 13-1. Main Assembly

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

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

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

2 176 106 LABEL, warning moving parts (CE models only) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

4Z1
4Z1

C

202 151 REACTOR, ac 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

C

201 514 REACTOR, ac 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 SR4, SR5 035 704 RECTIFIER, integ bridge 40. amp 800v 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 189 763 BRACKET, mtg air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 189 764 AIR CLEANER, intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

17 189 618 HOSE, air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 198 457 TUBE, air intake perkins 104.22 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 173 036 HOSE, elbow air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 863 CLAMP, hose 1.125 − 3.000 clp dia 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 189 464 SEAL, weather lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

21 201 658 UPRIGHT, center assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 191 819 HOSE, sae .312 id x .560 od x 14.000 (order by ft) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198 584 HOSE, sae .312 id x .560 od x 5.000 (order by ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 095 636 HOSE, sae .187 id x .41 od x 30.000 (order by ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 192 750 BASE, fuel filter w/adapter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 *192 744 FILTER, fuel spin-on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 192 741 BLOCK, spacer mtg filter base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 +201 934 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 ♦+202 640 COVER, top ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 189 052 GROMMET, plastic neck filler fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 190 198 CAP, tank screw-on 3.500 in w/vent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 192 041 LABEL, use diesel fuel only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 176 103 LABEL, use diesel fuel only (CE models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 108 487 LABEL, warning falling equipment 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 176 104 LABEL, warning falling equipment (CE models only) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 176 230 LABEL, warning hot exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 105 734 PIPE, muffler extension elbow 1.750 od 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 201 851 COVER, radiator access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 ♦202 629 COVER, radiator access ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 191 354 SUPPORT, cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 ♦202 633 SUPPORT, cover e-coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 010 875 CLAMP, muffler 2.000 dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 203 180 MANIFOLD, exhaust muffler perkins 104.22 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203 179 BRACKET, support muffler 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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38 209 393 ENGINE, Perkins dsl elec 404.22bw 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*215 093 SWITCH, coolant temperature 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*215 094 SWITCH, oil pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

023 562 CLAMP, hose .312 − .875 clp dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*197 899 FILTER, oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

*197 997 FILTER, fuel secondary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 202 017 GUARD, belt perkins 104.22 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 214 658 HOSE, radiator upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 *197 944 BELT, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 +215 006 GUARD, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 214 884 RADIATOR, W/14# Cap 4 Row Core 3 Pass 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 120 CAP, radiator pressure 14 lb 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214 885 SCHROUD, radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 201 749 UPRIGHT, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 ♦207 188 UPRIGHT, rear ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦207 005 GRILL, rear panel ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 190 206 CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 108 081 TERMINAL PROTECTOR, battery post mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 190 207 CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 203 430 BRACKET, battery holddown 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 190 897 BATTERY, stor 12V 650crk 110rsv gp 24 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 201 006 BOLT, j stl .312−18 x 8.500 pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 +201 183 COVER, battery access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 ♦+202 639 COVER, battery access ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 168 385 LABEL, warning battery explosion can blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 176 108 LABEL, warning battery explosion can blind (CE models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

53 201 996 LABEL, warning do not operate with guard missing 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 197 496 HOSE, radiator lower perkins 104.22 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

55 165 271 VALVE, oil drain 3/8-18NPTF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 176 529 FITTING, hose brs barbed fem 1/2tbg x 3/8NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 113 854 HOSE, SAE .500 ID x .780 OD xc oil (order by ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 197 448 FITTING, hose brs barbed elbow m 1/2 tbg x 3/8 npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 WASHER, oil drain (available through engine manufacturer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 197 196 FITTING, adapter oil drain 12mm male x 3/8 npt female 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 190 992 KEEPER, latch engine access door 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 190 076 CHANNEL, stiffener engine access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 ♦202 635 CHANNEL, stiffener engine access e-coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 199 592 LATCH, paddle series 20 (black) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 190 518 LABEL, diesel engine maintenance perkins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 200 778 LABEL, diesel engine maintenance Perkins (CE models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

65 +200 989 DOOR, engine access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 ♦+210 736 DOOR, engine access ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 189 975 HINGE, door access 180deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 190 190 TANK, coolant recovery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 208 141 STOP, door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 189 826 PANEL, rocker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 ♦199 298 PANEL, rocker ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 191 626 BUMPER, door engine access 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 189 827 PANEL, gen RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 199 300 PANEL, gen RH ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 199 849 SCREW, 625-11 x 4.00hexhd pln gr 5 pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 071 731 WASHER, flat .656 ID x 2.250 OD x .187T stl pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 197 489 BRACKET, mtg RH Perkins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197 488 BRACKET, mtg LH Perkins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 071 890 RETAINER, mount eng/gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Figure 13-1. Main Assembly (Continued)

76 071 730 TUBING, stl .875 OD x 12ga wall x 2.500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 083 476 MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 135 205 NUT, 625-11 .94hex .76H stl pld elastic stop nut 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 *197 997 FILTER, fuel secondary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 PUMP, fuel (available through engine manufacturer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 173 909 HOSE, sae .312 id x .560 od (order by ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 198 548 BRACKET, mtg fuel filter/pump 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 ♦198 624 IDLE SOLENOID ASSEMBLY (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049 839 Bracket, Adjustment Solenoid 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

080 517 Solenoid, 12vdc Pull Type Tubular 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203 716 Bracket, Mtg Solenoid 104.22 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

605 277 Pin, Cotter .093 X .750 Zinc Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198 370 Rod, Throttle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

206 209 Ball Joint, .250−28 Thd 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198 609 Arm, Throttle 104.22 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 013 367 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 176 106 LABEL, warning moving parts (CE models only) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 Figure13-6 GENERATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 095 636 HOSE, sae .312 id x .560 od x 14.000 (order by ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 218 087 TANK, fuel 23gal (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 124 253 BUSHING, tank fuel 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

89 189 912 FITTING, stl barbed elbow w/.047 in orf zinc pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

91 201 025 CAP, fuel fitting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 189 913 FITTING, stl barbed elbow zinc pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 190 142 SENDER, fuel gauge 9.7500 deep tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 189 910 FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 189 908 VALVE, drain fuel 180deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96 181 572 BUSHING, tank fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 191 446 EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) 6ft. . . . . . . . . . . . . . . . . . . . . . . . . .

98 190 179 PANEL, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 190 250 LABEL, warning do not weld on base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 200 864 LABEL, do not weld on base (CE models only) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 191 897 BRACKET, mtg unit 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 192 362 BRACKET, mtg nyl 1/2 conduit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 196 220 BRACKET, hold down fuel tank rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 +200 999 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 ♦+203 382 BASE e-coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 218 086 BRACKET, hold down fuel tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105 189 731 FIREWALL, lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106 Figures 13-2, 13-3 CONTROL BOX ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107 R2

C

189 699 RESISTOR, WW tap 375W 10 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

108 R3 189 699 RESISTOR, WW tap 375W 10 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109 +201 750 UPRIGHT, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109 ♦+202 637 UPRIGHT, front ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110 182 761 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110 176 105 LABEL, warning general precautionary (CE models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

111 13-4, 13-5 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112 202130 XFMR, current sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 190 010 LABEL, caution do not use ether 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 176 109 LABEL, caution using ether to aid engine (CE models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

114 191 448 TOP, cover front upright 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 ♦199 305 TOP, cover front upright ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115 Figure 13-7 MAIN RECTIFIER ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116
117 PC1

118 +147 923 LABEL, warning moving parts can cause serious injury 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-496 Page 74

C

193 453 BRACKET, mtg box fcr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V

C

189 143 MODULE, field current regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V

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4

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Figure 13-1. Main Assembly (Continued)

119 212 944 LABEL, weld control/arc condition information label 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 058 NUT, .250-20 u-nut multi-thread 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049 525 NUT, 312-18 u-nut multi-thread 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202 021 KIT, label (includes safety and informational labels) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 061 KIT, label (includes safety and informational labels) (CE models only) 1. . . . . . . . . . . . . . . . . . . . . .

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 202 021 or Label Kit 201 061 (CE models only).

*Recommended Spare Parts.

C

CC models only.

C

C

CC/CV models only.

V

♦Optional

T o 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.

18

6

3

17

7

2

1

11

8

23

15

10

9

16

5

13

12

21

19

22

20

Ref. 802 551-E

Figure 13-2. Control Box Assembly − CC Models

No.

Mkgs.

No.

Description

Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 106)

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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OM-496 Page 75

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Figure 13-2. Control Box Assembly − CC Models (Continued)

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204 812 HARNESS, control box, weld control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 CR7 188 636 RELAY, OCV control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 D1/C1 189 701 DIODE/CAPACITOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 SR1, SR2 035 704 RECTIFIER, integ 40A 800V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CR5 090 104 RELAY, encl 12VDC SPST 30A/15VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S5 011 609 SWITCH, tgl spdt 15a 125vac on−none−on spd term chr. . . . . . . . . . . . . . . . . . . .

(located on front panel, see 13-4) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S6 011 622 SWITCH, tgl 3pdt 15a 125vac on−none−on spd term. . . . . . . . . . . . . . . . . . . .

(located on front panel, see 13-4 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 CIRCUIT BREAKER, man reset 1P 15A 250VAC frict 3. . . . . . . . . . . . . . . . . . . . .

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

PLG3 158465 CONN, rect univ 084 12p/s 3row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187654 SEAL, wire univ 12p/s 3row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 114063 CONN, rect univ 084 4p/s 1row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192309 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 ♦090104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 CR2, CR3, CR9 090 104 RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg 3. . . . . . . . . . . . . . . . . . .

212 452 HARNESS, engine control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 D10/C10, D11/C11 189 701 DIODE/CAPACITOR BOARD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 R8 217 335 RESISTOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 CR1 214 876 RELAY, Encl 6vdc Spst 35a/14vdc 5 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 CR8 155 309 CONTACTOR, Solenoid 12vdc Continuous 400a Inrush 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-496 Page 76

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20

3

15

18

17

2

1

11

19

21

12

7

6

8

9

5

13

10

14

Figure 13-3. Control Box Assembly − CC/CV Models

No.

Mkgs.

No.

Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 106)

Description

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 134 201 STAND-OFF, support pc card 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PC9 192 224 CIRCUIT CARD ASSY, display 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 C9 087 110 CAPACITOR, elctlt 240uf 200VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 177 136 CLAMP, capacitor 1.375dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204 811 HARNESS, control box, cv weld control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 SR1 035 704 RECTIFIER, integ 40A 800V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 CR5 090 104 RELAY, encl 12VDC SPST 30A/15VDC 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. . . . . . . . . . . . . . . . . . . . . . . . .

12 CB11, 12, 13 139 266 CIRCUIT BREAKER, man reset 1P 15A 250VAC frict 3. . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S6 193 324 SWITCH, rotary 6 position gold contacts. . . . . . . . . . . . . . . . . . .

(located on front panel, see 13-5) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S5 011 609 SWITCH,tgl spdt 15a 125vac on−none−on spd term chr. . . . . . . . . . . . . . . . . . . .

(located on front panel, see 13-5) 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Figure 13-3. Control Box Assembly − CC/CV Models (Continued)

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 PC7 ♦195 706 MODULE, pull to idle, two output, 7 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CR4 ♦113 247 RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CR6 ♦090104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR2, CR3, CR9 090 104 RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg 3. . . . . . . . . . . . . . . . . . .

16

212 452 HARNESS, engine control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 D10/C10, D11/C11 189 701 DIODE/CAPACITOR BOARD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 R8 217 335 RESISTOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185 655 SEAL, wire univ 15P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 CR1 214 876 RELAY, Encl 6vdc Spst 35a/14vdc 5 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 CR8 155 309 CONTACTOR, Solenoid 12vdc Continuous 400a Inrush 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-496 Page 78

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Figure 13-4. Panel, Front w/Components − CC Models

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Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 111)

1 201 841 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 201 580 PANEL, engine/weld control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦202 642 PANEL, engine/weld control ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S3 189 382 SWITCH, range/changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦202 223 BUS BAR, idealized 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 13-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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802 266-D

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Figure 13-4. Panel, Front w/Components − CC Models (Continued)

8 S5 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in. . . . . . . . . . . . . . .

control box harness, see 13-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 RC13 032 897 RECEPTACLE, twlk grd 2P3W 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 045 COVER, receptacle twistlock for RC13 − (CE models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 S1 176 606 SWITCH, ignition 4posn w/o handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 S2 021 467 SWITCH, tgl spst 3a 250v off−none−(on) spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 MS1 189 698 SWITCH, magnetic manual reset low current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 553 CLIP, circuit breaker retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CB1 201 083 CIRCUIT BREAKER, man reset 2P 20 A, 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 109 HARNESS, generator power (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CB2 093 996 CIRCUIT BREAKER, man reset 1P 20A 250VAC frict 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 GFCI1 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

16 RC1 147 632 RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 053 HARNESS, generator power (CE models only) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CB2 093 996 CIRCUIT BREAKER, man reset 1P 20A 250VAC frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CB3 139 266 CIRCUIT BREAKER, man reset 1P 15A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 GFCI1 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

16 RC1 176 355 RECEPTACLE, str 2p3w 16a 220v flange mtg (CE models only) 1. . . . . . . . . . . . . . . . . .

17 190 861 LABEL, warning electric shock and moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 200 910 LABEL, warning, electric shock and moving parts (CE models only) 1. . . . . . . . . . . . . . . . . . . . .

18 +201 106 PANEL, gen pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 ♦+202 641 PANEL, gen pwr ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 ♦+201 052 PANEL, gen pwr (CE models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 ♦+210 750 PANEL, gen pwr ss (CE models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 083 030 STUD, brs .250−20 x 1.750 w/hex collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 601 836 NUT, 250−20 .50hex .19h brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 ♦196 073 LABEL, do not switch while welding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 S12 ♦195 825 SWITCH, polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 201 125 PANEL, mtg terminal pwr output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 ♦199 303 PANEL, mtg terminal pwr output ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 735 WASHER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 181 169 SPACER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 186 621 BOOT, generic output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 ♦059 773 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 ♦010 647 PIN, spring cs .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 193 260 COVER, receptacle 2.250 dia lexan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 193 258 COVER, receptacle GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 190 323 BOOT, circuit breaker clear hex nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 193 143 BOOT, magnetic shutdown switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 021 385 BOOT, toggle switch lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 119 014 LEVER, switch black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 PL1 191 241 LED, red 12V 4 ind lights panel mtg round 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 FUEL 192 265 GAUGE, fuel elec switch w/o sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 HM 118 058 METER, hour 12-24VDC 2.25dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 ♦193 228 METER, Volt Dc 8− 18 Scale 2.250 In Black Face 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 ♦193 229 GAUGE, Coolant Temp 0− 300 Deg F Electric Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦193 231 SENDER, Coolant Temp 300 Deg F 1/2−14 Npt. . . . . . . . . . . . . . . . . . .

(Perkins 3.152 engine only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦197 798 SENDER, Coolant Temp 300 Deg F M16 X 1.5. . . . . . . . . . . . . . . . . . .

(Perkins 104.22 engine only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 ♦193 227 GAUGE, Pressure Oil 0−100 Psi Electric Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦193 230 SENDER, Pressure Oil 0− 100 Psi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 ♦194 348 AMMETER, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦030 084 SHUNT, Meter 50mv 600 Amp Lt Wt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-496 Page 80

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Figure 13-4. Panel, Front w/Components − CC Models (Continued)

43 ♦194 345 VOLT METER, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 189 161 HANDLE, switch range 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 010 647 PIN, spring CS .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 019 602 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

024 103 BLANK, snap−in nyl .750 mtg hole black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 202 021 or Label Kit 201 061 (CE models only).

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

 Hardware is common and

not available unless listed.

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3

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Figure 13-5. Panel, Front w/Components − CC/CV Models

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802 332-F

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Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 111)

1 201 579 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 201 580 PANEL, engine/weld control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦202 642 PANEL, engine/weld control ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S3 189 382 SWITCH, range/changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦202223 BUS BAR, idealized 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 S6 193 234 SWITCH, rotary 6 position gold contacts (included in control box harness,. . . . . . . . . . . . . .

see 13-3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 S5 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in. . . . . . . . . . . . . . .

control box harness, see 13-3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 202 209 SPACER, nylon 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PC6 192 995 CIRCUIT CARD ASSY, connector/receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CB5 139 266 CIRCUIT BREAKER, man reset 1p 15a 250vac frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 S1 176 606 SWITCH, ignition 4posn w/o handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 S2 021 467 SWITCH, tgl spst 3a 250v off−none−(on) spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 MS1 189 698 SWITCH, magnetic manual reset low current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CB1 201 083 CIRCUIT BREAKER, man reset 2P 20 A, 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 553 CLIP, circuit breaker retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 109 HARNESS, generator power (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CB2 093 996 CIRCUIT BREAKER, man reset 1P 20A 250VAC frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 GFCI1 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

17 RC1 147 632 RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 053 HARNESS, generator power (CE models only) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CB2 093 996 CIRCUIT BREAKER, man reset 1P 20A 250VAC frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CB3 139 266 CIRCUIT BREAKER, man reset 1P 15A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 GFCI1 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

17 RC1 176 355 RECEPTACLE, str 2p3w 16a 220v flange mtg (CE models only) 1. . . . . . . . . . . . . . . . . .

18 RC5 ♦182 954 RCPT, str 3P4W 50A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 ♦025 248 STAND-OFF, insul .250-20 x 1.2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 ♦604 102 CONNECTOR, clamp cable 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 ♦197 527 GUARD, circuit breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 ♦197 363 TERMINAL, ring tng screw clamp 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 CB7 ♦196 780 CIRCUIT BREAKER, man reset 3p 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 +201 106 PANEL, generator power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 +201 052 PANEL, gen pwr (CE models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 ♦202 641 PANEL, generator power ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 +♦201 107 PANEL, generator power (full kVA option) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 ♦196 781 BOOT, circuit breaker 3 pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 ♦197 508 PLUG, protective 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 ♦077 440 BUSHING, conduit 1 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 601 836 NUT, 250−20 .50hex .19h brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 ♦197 291 COVER, receptacle w/gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 083 030 STUD, brs .250−20 x 1.750 w/hex collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CT2 ♦197 433 TRANSFORMER, current sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 190 861 LABEL, warning electric shock and moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 200 910 LABEL, warning, electric shock and moving parts (CE models only) 1. . . . . . . . . . . . . . . . . . . . .

31 ♦197 399 LABEL, warning 3 ph generator power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 193 260 COVER, receptacle 2.250 dia lexan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 193 258 COVER, receptacle GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 190 323 BOOT, circuit breaker clear hex nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 S12 ♦195 825 SWITCH, polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S12 ♦211 137 SWITCH, polarity/AC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 201 125 PANEL, mtg terminal pwr output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-496 Page 82

Return To Table Of Contents

Quanti

Part

Dia.

Item

No.

ty

Mkgs.

No.

Description

Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)

36 199 303 PANEL, mtg terminal pwr output ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 PC4, PC5 189 744 CIRCUIT CARD ASSEMBLY, filter hf 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 735 WASHER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 134 201 STAND-OFF, support 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 181 169 SPACER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 186 621 BOOT, generic output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 ♦059 773 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 ♦010 647 PIN, spring cs .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 ♦196 073 LABEL, do not switch while welding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 193 143 BOOT, magnetic shutdown switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 021 385 BOOT, toggle switch lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 119 014 LEVER, switch black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 190 323 BOOT, circuit breaker clear hex nut 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 170 391 CONN, circ ms protective cap size 20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 PL1 191 241 LED, red 12V 4 ind lights panel mtg round 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 FUEL 192 265 GAUGE, fuel elec switch w/o sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 HM 118 058 METER, hour 12-24VDC 2.25dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 ♦193 228 METER, Volt Dc 8− 18 Scale 2.250 In Black Face 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 ♦193 229 GAUGE, Coolant Temp 0− 300 Deg F Electric Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦193 231 SENDER, Coolant Temp 300 Deg F 1/2−14 Npt. . . . . . . . . . . . . . . . . . .

(Perkins 3.152 engine only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦197 798 SENDER, Coolant Temp 300 Deg F M16 X 1.5. . . . . . . . . . . . . . . . . . .

(Perkins 104.22 engine only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 ♦193 227 GAUGE, Pressure Oil 0−100 Psi Electric Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦193 230 SENDER, Pressure Oil 0− 100 Psi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 ♦194 348 AMMETER, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦030 084 SHUNT, Meter 50mv 600 Amp Lt Wt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 ♦194 345 VOLT METER, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 097 922 KNOB, pointer .875 dia x .250 ID w/set screws plstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 189 161 HANDLE, switch range 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 010 647 PIN, spring CS .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 097 924 KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 CB6 083 432 CIRCUIT BREAKER, Man Reset 1p 10a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 158 HARNESS, unit weld control − CV (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 114 063 CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8 193 184 CONNECTOR, rect cinch 30 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG13 147 992 CONNECTOR, rect univ 039 10p/s 2 row plug cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 158 465 CONNECTOR, rect univ 084 12p/s 3 row plug cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

088 731 BUSHING, snap-in nyl .375 ID x .500 mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135 873 CLIP, conduit convoluted 1/2 in mtg hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 654 SEAL, wire univ 12p/s 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

024 103 BLANK, snap-in nyl .750 mtg hole blk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 304 BLANK, snap−in nyl .250 mtg hole black 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional

Quanti

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 202 021 or Label Kit 201 061 (CE models only).

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.

Return To Table Of Contents

OM-496 Page 83

 Hardware is common and

1

Part

Dia.

Item

ty

not available unless listed.

20

11

12

27

26

10

25

9

8

7

6

5

3

4

2

28

29

30

31

32

33

34

35

36

13

14

24

16

15

17

18

21

19

22

23

802 552-B

Figure 13-6. Generator

No.

Mkgs.

No.

Description

Quanti

Figure 13-6. Generator (Figure 13-1 Item 85)

1 132 053 SCREW, .375−16x1.50 hex hd−pln gr5 pld 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 183 387 WASHER, conical spring .406 ID x .875 OD pltd 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 195 911 ENDBELL, gen (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 143 220 O-RING, 2.859 ID x .139CS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 201 099 STATOR, exciter/gen pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 +201 110 STATOR, weld assembly complete 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6+♦201 089 STATOR, weld assembly complete (full kVA option) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 013 367 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 176 106 LABEL, warning moving parts (CE models only) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 190 197 GUARD, generator wire mesh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 172 674 SPRING, ext .240 OD x .041 wire x 3.500pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 039 207 BAFFLE, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 ROTOR 212 996 ROTOR, Generator Segmented Assy (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 210 824 ROTOR, Generator (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 024 617 RING, Rtng Ext 1.375 Shaft X .050 Thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 053 390 BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X .6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HUB, Drive (Not Sold Separately) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210 447 FAN, Rotor Assy Generator (Segmented) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 210 332 PLATE, Flex Hubmount 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 206 242 FAN, Rotor Segmented Assy Gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 049 026 SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 080 389 SCREW, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 197 487 FLYWHEEL, Perkins 104.22 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-496 Page 84

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Part

Dia.

Item

No.

ty

Mkgs.

No.

Description

Quanti

Figure 13-6. Generator (Continued)

21 197 486 ADAPTER, Engine Perkins 104.22 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 049 026 SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 191 579 COVER, starter hole Perkins/Continental 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

195 560 GUARD, starter hole deutz 912 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 172 555 SCREW, M10-1.5 x 50hexhd pln 8.8pld 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 602 159 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 601 961 SCREW, .312-18 x 2.25hexhd pln gr 5pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 602 211 WASHER, lock .318 ID x 0.586 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 139 341 WASHER, exciter 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 *190 823 BRUSH, contact 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 208 469 CLIP, spring 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 189 142 BRUSHHOLDER ASSEMBLY, gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 602 242 WASHER, flat .375IDx0.875odx.083t stl pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 602 211 WASHER, Lock .318idx0.586odx.078t Stl Pld Split.312 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 604 534 SCREW, .312−18x1.25 hex hd−pln gr5 pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 259 HARNESS, brush (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 168 071 CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . .

187 651 SEAL, wire univ 9P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order

label individually or as part of Label Kit 202 021 or Label Kit 201 061 (CE models only).

*Recommended Spare Parts.
♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Return To Table Of Contents

OM-496 Page 85

 Hardware is common and

Part

Dia.

Item

ty

not available unless listed.

1

4

3

2

5

6

7

8

9

802 279-A

Figure 13-7. Main Rectifier Assembly

No.

Mkgs.

No.

Description

Quanti

Figure 13-7. Main Rectifier Assembly (Figure 13-1 Item 115)

SR3 201 747 RECTIFIER (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SR3 ♦203 381 RECTIFIER, environmental (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 188 137 CONNECTION BOARD, rectifier AC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 188 517 BUS BAR, connection board 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 188 135 ENCLOSURE, rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 134 201 STAND-OFF, support 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PC3 201 449 CIRCUIT CARD ASSEMBLY, protection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 188 136 INSULATOR, heat sink 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 188 493 HEAT SINK, rectifier al 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 D3, D5, D7 208 334 DIODE, rect 275A 300V SP 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 D2, D4, D6 208 335 DIODE, rect 275A 300V RP 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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-496 Page 86

Return To Table Of Contents

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

Y our distributor also gives
you ...

Service

Y ou always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

Effective January 1, 2003

(Equipment with a serial number preface of “LC” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers
* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
* Intellitig
* Maxstar 150
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by
the engine manufacturer .)

3. 1 Year — Parts and Labor Unless Specified

* DS-2 Wire Feeder
* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources
* Water Coolant Systems
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Maxstar 85, 140
* Spot Welders
* Load Banks
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers

Miller’s True Blue Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on B o b cat, Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation bas e d u p o n a c tual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. I N N O EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.

miller_warr 8/03

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

Miller Electric Mfg. Co.

An Ill inoi s Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters− USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.