Miller Electric Big Blue 400 KX User Manual

OM-4423 215 178N

September 2005

Processes

Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A)
Cutting and Gouging

Description

Engine Driven Welding Generator

)

Big Blue 400 KX

Visit our website at

www.MillerWelds.com

File: Engine Drive

From Miller to You

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

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

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

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

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

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

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

Working as hard as you do

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

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

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

Mil_Thank 4/05

TABLE OF CONTENTS

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

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

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

1-3. Engine Hazards 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. Proposition californienne 65 Avertissements 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

3-1. Warning Label Definitions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Manufacturer’s Rating Label 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Symbols And Definitions 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Weld, Power, And Engine Specifications 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Dimensions, Weights, And Operating Angles 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Volt-Ampere Curves 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Fuel Consumption 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Duty Cycle And Overheating 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. AC Generator Power Curve 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Mounting Welding Generator 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Installing Exhaust Pipe 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Activating The Dry Charge Battery (If Applicable) 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Connecting The Battery 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Engine Prestart Checks 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Connecting To Weld Output Terminals 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Selecting Weld Cable Sizes* 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Connecting To Remote 14 Receptacle RC14 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING WELDING GENERATOR 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Front Panel Controls (See Section 6-2) 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Description Of Front Panel Controls (See Section 6-1) 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Process/Contactor Switch On CC/CV Models 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Lift-ArcE Start Procedure 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Remote Voltage/Amperage Control 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − OPERATING AUXILIARY EQUIPMENT 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. 110 Volt Receptacles 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 8 − MAINTENANCE & TROUBLESHOOTING 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Routine Maintenance 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Maintenance Label 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Servicing Air Cleaner 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Inspecting And Cleaning Spark Arrestor Muffler 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Servicing Engine Cooling System 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Adjusting Engine Speed On Standard Models 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Servicing Fuel And Lubrication Systems 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8. Overload Protection 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9. Checking Generator Brushes 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10. Voltmeter/Ammeter Help Displays 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-11. Troubleshooting 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − ELECTRICAL DIAGRAMS 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − RUN-IN PROCEDURE 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Wetstacking 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Run-In Procedure Using Load Bank 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Run-In Procedure Using Resistance Grid 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − GENERATOR POWER GUIDELINES 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − PARTS LIST 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declaration of Conformity for

European Community (CE) Products

NOTE

Manufacturer: European Contact:

Miller Electric Mg. Co. Mr. Danilo Fedolfi,
1635 W. Spencer St. Managing Director
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
Phone: [phone] Via Privata Iseo 6/E

European Contact Signature:

Declares that the product: Big Blue 400 KX

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

20098 San Giuliano
Milanese, Italy
Phone: [phone]
Fax: [phone]

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

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

Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC

Noise level of Welding Generators: 2000/14/EC

Standards

Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1

Rotating Electrical Machines − Part 1: Rating and Performance.

IEC 60034-1 Ed. 10.2 1999-08

Rotating Electrical Machines − Part 5: Classification Of Degrees Of Protection Provided By Enclosure Of Rotating

Electrical Machines (IP Code) IEC 60034-5 2001-06

Insulation Coordination For Equipment Within Low-Voltage Systems:

Part 1: Principles, Requirements and Tests: IEC 60664-1 Ed. 1.1 2000-04

Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10 August 2002

The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.

dec_rot_6/05

Declaration of Conformity for

European Community (CE) Products

NOTE

Manufacturer: European Contact: Notified Body:

Miller Electric Mg. Co. Mr. Danilo Fedolfi, AV Technology Limited
1635 W. Spencer St. Managing Director AVTECH House
Appleton, WI 54914 USA MILLER Europe S.r.l. Birdhall Lane
Phone: [phone] Via Privata Iseo 6/E Cheadle Heath

European Contact Signature:

The Manufacturer Declares the: Big Blue 400 KX

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

20098 San Giuliano Stockport, Chesire SK30XU
Milanese, Italy
Phone: [phone]
Fax: [phone]

Conforms to Directive: 2000/14/EC, Noise Level of Welding Generators

Effective Date: 7/2004

Sound Level Information

Measured Sound Power Level: 97 dB

Guaranteed Sound Power Level: 98 dB

Sound power level requirements determined by the 30% duty cycle of 400 A, 23 V

Conforming assessment procedure 1 of Annex VI will be followed.

The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.

dec_rotsound_1/05

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

 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.

rom _nd_3/05

 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.

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

once. Maintain unit according to manual.

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

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.

 Do not touch electrode holders connected to two welding machines at

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

 Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Clamp work cable with good metal-to-metal contact to workpiece or 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 local forced ventilation at the arc to

remove welding fumes and gases.

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

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

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

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

 Do not weld in locations near degreasing, cleaning, or spraying 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 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 an approved welding helmet fitted with a proper shade of filter lenses

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

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

sparks; warn others not to watch the arc.

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

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

OM-4423 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.

 Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not

possible, tightly cover them with approved covers.

 Do not weld where flying sparks can strike flammable material.

 Protect yourself and others from flying sparks and hot metal.

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

through small cracks and openings to adjacent areas.

 Watch for fire, and keep a fire extinguisher nearby.

 Be aware that welding on a ceiling, floor, bulkhead, or partition can cause

fire on the hidden side.

 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, sparks, and fire hazards.

 Do not use welder to thaw frozen pipes.

 Remove stick electrode from holder or cut off welding wire at contact tip

when not in use.

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

 Do not touch hot parts bare handed.
 Allow cooling period before working on equipment.
 To handle hot parts, use proper tools and/or wear

heavy, insulated welding gloves and clothing to pre­vent burns.

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, physical damage, slag, open flames, sparks, and arcs.

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

cylinder rack to prevent falling or tipping.

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

 Use the right equipment, correct procedures, and sufficient number of per-

sons to llift and move cylinders.

 Read and follow instructions on compressed gas cylinders, associated

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

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-4423 Page 2

MOVING PARTS can cause injury.

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

and securely in place.

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

maintenance and troubleshooting as necessary.

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

battery cable from battery.

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

before starting engine.

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

engine from kicking back or starting.

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

nents.

HOT PARTS can cause severe burns.

 Do not touch hot engine parts.
 Allow cooling period before maintaining.
 Wear protective gloves and clothing when working on

a hot engine.

STEAM AND HOT COOLANT can burn.

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

avoid scalding.

 Always check coolant level at overflow tank, if 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

BREATHING COMPRESSED AIR can
cause serious injury or death.

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

COMPRESSED AIR can cause injury.

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

TRAPPED AIR PRESSURE AND WHIPPING
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.

 Use only genuine Miller/Hobart replacement parts.

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

FALLING UNIT can cause injury.

 Use lifting eye to lift unit and properly installed acces-

sories only. Do not exceed maximum lift eye weight
rating (see Specifications).

 Lift and support unit only with proper equipment and

correct procedures.

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

enough to extend beyond opposite side of unit.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or 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,
and body protection.

 Sparks can cause fires — keep flammables away.

OVERUSE can cause OVERHEATING.

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

to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to store,

move, or ship PC boards.

TILTING OF TRAILER can cause injury.

 Use tongue jack or blocks to support weight.
 Properly install welding generator onto trailer accord-

ing to instructions supplied with trailer.

OM-4423 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

 Welding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)

 Battery posts, terminals and related accessories contain lead

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

 Electromagnetic energy can interfere with sensitive

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

 Be sure all equipment in the welding area is 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, or
shielding the work area.

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

California to cause cancer, birth defects, or other reproductive
harm.

For Diesel Engines:
 Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and
other reproductive harm.

1-7. Principal Safety Standards

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

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

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

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, P.O. Box 9101, 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 Magnetic Fields

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

OM-4423 Page 4

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, NFPA 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.

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 before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

 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

TRIQUES, 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.

Ce groupe de symboles signi­fie Mise en garde ! Soyez vigi­lant ! Il y a des risques de dan­ger reliés aux CHOCS ÉLEC-

rom_fre 3/05

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

manuel pour attirer votre attention et identifier les risques de danger.
Lorsque vous voyez un symbole, soyez vigilant et suivez les directives
mentionnées afin d’éviter tout danger. Les consignes de sécurité pré­sentées ci-après ne font que résumer l’information contenue dans les
normes de sécurité énumérées à la section 2-7 . Veuillez lire et respecter
toutes ces normes de sécurité.

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

confiés qu’à des personnes qualifiées.

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

lièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

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

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

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

trous.

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

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

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

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

 Se servir d’une source électrique à courant électrique UNIQUEMENT si le

procédé de soudage le demande.

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

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

 Des précautions de sécurité supplémentaires sont requises dans des 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.

 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 endom-

magé 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.

 Ne pas toucher des porte électrodes connectés à deux machines en même

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

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

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

l’appareil sont également sous tension à ce moment-là. En

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

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

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

tout objet métallique.

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

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

me 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’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de

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

 Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.
 Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et les

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

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

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

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

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

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

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

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

 Fermer l’alimentation du gaz protecteur en cas de non utili-

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

teur d’adduction d’air homologué.

sation.

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 des

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

 Porter un casque de soudage approuvé muni de verres filtrants approprié

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

 Porter des lunettes de sécurité avec écrans latéraux même sous votre cas-

que.

 Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les au-

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

 Porter des vêtements confectionnés avec des matières résistantes et ignifu-

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

rayons visibles et invisibles intenses (ultraviolets et infrarou-

OM-4423 Page 5

LE SOUDAGE peut provoquer un in­cendie ou une explosion.

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

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.

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

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

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

substances inflammables.

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

chaud.

 Des étincelles et des matériaux chauds du soudage peuvent facilement

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

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

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

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

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

ou couper le fil à la pointe de contact.

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

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

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

qu’un allumeur au butane ou des allumettes.

 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.

éclatement. Des étincelles peuvent être projetées de l’arc de

DES PARTICULES VOLANTES
peuvent blesser les yeux.

 Le soudage, l’écaillement, le passage de la pièce à la bros-

se en fil de fer, et le meulage génèrent des étincelles et des

froidissement des soudures, elles risquent de projeter du laitier.

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

particules métalliques volantes. Pendant la période de re-

 Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et por-

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, des dommages physiques, 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 électri-

ques.

 Ne jamais placer une torche de soudage sur une bouteille à gaz.
 Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
 Ne jamais souder une bouteille pressurisée − risque d’explosion.
 Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et rac-

cords 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.

 Utiliser les équipements corrects, les bonnes procédures et suffisamment de

personnes pour soulever et déplacer les bouteilles.

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

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

2-3. Dangers existant en relation avec le moteur

L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gants en caout-

chouc 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 véhicu-

les 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 carburant

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

flamme nue.

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

expansion.

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

renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.

ou de faire le plein.

DES ORGANES MOBILES peuvent pro­voquer des blessures.

 Ne pas approcher les mains des ventilateurs, courroies et

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

ments et dispositifs de protection.

OM-4423 Page 6

autres pièces en mouvement.

 Arrêter le moteur avant d’installer ou brancher l’appareil.
 Seules des personnes qualifiées sont autorisées à enlever les portes, pan-

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

 Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,

débrancher le câble négatif (−) de batterie de la borne.

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

mobiles.

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

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

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

route accidentelle du moteur.

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

générateur.

 Porter des gants et des vêtements de protection pour travailler sur un

moteur chaud.

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

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

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chaudes.
 Prévoir une période de refroidissement avant de travailler à

l’équipement.

ter des gants de soudage et des vêtements épais pour éviter les brûlures.

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 ni-

veau sonore 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

DES PIECES CHAUDES peuvent provo­quer des brûlures et blessures.

 Ne pas toucher les parties chaudes du moteur.
 Laisser l’ensemble se refroidir avant d’effectuer la

maintenance.

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.

 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.
 Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon

du radiateur.

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

ver le bouchon.

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

 Fermer l’alimentation du gaz protecteur en cas de non

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

rateur d’adduction d’air homologué.

utilisation.

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

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

2-4. Dangers liés à l’air comprimé

LA CHALEUR DU MOTEUR peut pro-
voquer un incendie.

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

 Tenir à distance les produits inflammables de l’échappement.

surfaces inflammables.

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.

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

 Ne pas utiliser l’air comprimé pour respirer.
 Utiliser l’air comprimé seulement pour le coupage, gou-

geage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer
des blessures.

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

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

nance.

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 in-

flammables.

 Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provo­quer des brûlures et blessures.

 Ne pas toucher le compresseur ou d’autres éléments

du circuit air comprimé chauds.

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

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

me 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.

 Utiliser uniquement des pièces de rechange Miller/Hobart.

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’ef-

fectuer la maintenance.

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

LA CHUTE DE L’APPAREIL peut blesser.

 Utiliser un œilleton de levage pour lever l’appareil et les

accessoires correctement installés. Ne pas dépasser
le poids nominal maximal de l’œilleton (voir les
spécifications).

 Ne lever et ne soutenir l’appareil qu’avec de l’équipement

approprié et en suivant les procédures adéquates.

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

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

LE SURCHAUFFEMENT peut endom­mager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant de démarrer ou

 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.

d’arrêter le moteur.

 Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer

ou expédier des cartes de circuits imprimes.

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.

LES ÉTINCELLES VOLANTES risquent
de provoquer des blessures.

 Porter un écran facial pour protéger le visage et les yeux.

 Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protec-

teurs. Cette manœuvre 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 in-

flammable.

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 com-

me indiqué dans le manuel s’y rapportant.

OM-4423 Page 7

LIRE LES INSTRUCTIONS.

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

(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

 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 un blindage pour réduire les interférences
éventuelles.

sécurité et les ordinateurs.

2-6. Proposition californienne 65 Avertissements

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

 L’énergie électromagnétique risque de provoquer des in-

terférences pour l’équipement électronique sensible tel
que les ordinateurs et l’équipement commandé par ordi-

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

électromagnétiquement.

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

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

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

tronique sensible.

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

ment à ce mode d’emploi.

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

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

nateur tel que les robots.

 Les équipements de soudage et de coupage produisent des fumées et

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

 Les batteries, les bornes et autres accessoires contiennent du plomb et

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

2-7. Principales normes de sécurité

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

Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping, American Welding Society Standard AWS F4.1

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

National Electrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de
Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet
: www.cganet.com).

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

2-8. Information EMF

Pour les moteurs à essence :

 Les gaz d’échappement des moteurs contiennent des produits chimi-

ques dont l’État de Californie reconnaît qu’ils provoquent des cancers
et des malformations congénitales ou autres problèmes de procréation.

Pour les moteurs diesel :

 Les gaz d’échappement des moteurs diesel et certains de leurs compo-

sants sont reconnus par l’État de Californie comme provoquant des
cancers et des malformations congénitales ou autres problèmes de pro­création.

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :
800-463-6727 ou à Toronto 416-747-4044, site Internet :
www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.ansi.org).

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

Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).

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

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

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

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

OM-4423 Page 8

procédures suivantes :

1. Maintenir les câbles ensemble en les tordant ou en les envelop­pant.

2. Disposer les câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.

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

5. Connecter la pince sur la pièce aussi près que possible de la sou­dure.

En ce qui concerne les stimulateurs cardiaques

Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder ou d’approcher des opérations de soudage. Si le médecin
approuve, il est recommandé de suivre les procédures précédentes.

SECTION 3 − DEFINITIONS

3-1. Warning Label Definitions

1

2

3

4

5

0 − 50 h Std.

50 h Std.

+

DIESEL

200A

S-177 571

+

0 − 200A

1 Remove unit from shipping

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

2 Read Owner’s Manual. Read

labels on unit.

3 Use Diesel Fuel only, and fill

fuel tank. Leave room for
expansion.

4 Warning! Watch Out! There

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

5 Check oil level. Add oil if

necessary.

6 During the first 50 hours of

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

7 After the first 50 hours of

operation, change the oil and
oil filter.

Notes

API CD-MIL L 2104D,

CD/SE, CD/SF

3/96

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4423 Page 9

3-2. Manufacturer’s Rating Label

OM-4423 Page 10

218 449−C

3-3. Symbols And Definitions

NOTE

A

Some symbols are found only on CE products.

Stop Engine

Starting Aid

(Preheat)

Check Injectors/

Pump

Positive Negative

Amperes

Fast (Run, Weld/

Battery (Engine)

Check Valve

V

Engine

Stick (SMAW)

Welding

Air Temperature Or

Temperature

Constant Current

Power)

Clearance

Volts Panel/Local Remote

Engine

(CC)

Slow (Idle) Start Engine

Engine Oil

Pressure

Fuel

Certified/Trained

Mechanic

Output

MIG (GMAW)

Welding

Engine Oil

Protective Earth

(Ground)

Welding Arc

Alternating

Current

TIG (GTAW)

3

X

n

Time

h

Three Phase

Electrode

Connection

Duty Cycle

Rated Idle

1

Speed n

Contactor On Arc Force (Dig) Lift-Arc TIG

U

0

0

Hours

Read Operator’s

Manual

Work Connection

Rated No Load

Voltage (Average)

Rated No Load

Speed

s

G

3

U

I

Seconds

Circuit Breaker

Engine-Driven,

Three-Phase

Alternator With

Rectifier

Conventional

2

Load Voltage

Current

1

Hz

n

I

2

Single Phase

Do Not Switch
While Welding

Hertz

Rated Load

Speed

Rated Welding

Current

OM-4423 Page 11

SECTION 4 − SPECIFICATIONS

20 410 A

10 kVA/kW, 91/46 A

3

F

11.5 gal

tip

A

°

D

4-1. Weld, Power, And Engine Specifications

Maximum

Welding

Mode

Weld Output

Range

Rated Welding

Output

Open-

Circuit

Voltage

Generator Power

Rating

Engine

Fuel

Capacity

CC/DC

CV/DC 14 − 40 V

20 − 410 A

300 A, 32 Volts DC

60% Duty Cycle

250 A, 30 Volts DC

100% Duty cycle

300 A, 29 Volts DC

60% Duty Cycle

250 A, 26.5 Volts DC

100% Duty cycle

7

110/55 V AC Receptacles

220 V AC Receptacles

4-2. Dimensions, Weights, And Operating Angles

Dimensions

32 in (813 mm)

Height

Width

Depth 56 in (1422 mm)

A 56 in (1422 mm)
B 54 in (1372 mm)
C 52 in in (1321 mm)
D 2 in (51 mm)
E 26 in (660 mm)
F 7/8 in (22 mm)
G 27-3/4 in (705 mm)

H

No fuel: 1040 lb (471 kg)

w/ fuel: 1139 lb (516 kg)

Lifting Eye Weight Rating

1500 lb (680 kg) Maximum

35-3/4 in (908 mm)

(to top of lift eye)

26-1/4 in (667 mm)

(mtg. brackets turned in)

28-3/4 in (730 mm)

(mtg. brackets turned out)

9/16 in (14 mm) Dia.

4 Holes

Weight

G

A

B

C

H

Front Panel End

E

Single-Phase,

10 kVA/kW, 91/46 A,

110/220 V AC,

60 Hz

5.3 kVA/kW, 48/96 A

10.5 kVA/kW, 48 A

 Do not exceed tilt angles or engine could

be damaged or unit could tip.

 Do not move or operate unit where it could

20
20°

F

,

Kubota 1505 EBG1

Water-Cooled,

20.2 HP Diesel Engine

.

°

-

our-Cylinder,

11.5 gal
(43.5 L)

30°

30°

OM-4423 Page 12

4-3. Volt-Ampere Curves

A. Stick Mode

100

90
80
70

60
50
40

DC VOLTS

30
20

MIN

10

0

0 100 200 300 400 500

B. MIG Mode

100

DC AMPERES

300

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

MAX

80

60

40

DC VOLTS

20

0

0 100 200 300 400 500

C. TIG Mode

100

80

60

DC AMPERES

40

DC VOLTS

20

MIN

0

0 100 200

300

DC AMPERES

MAX300

400 500

217 517 / 217 516 / 217 518

OM-4423 Page 13

4-4. Fuel Consumption

2.00

1.75

1.50

1.25

1.00

0.75

U.S. GAL/HR.

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

4-5. Duty Cycle And Overheating

100% Duty Cycle At 250 Amperes

Continuous Welding

1000

800

217 509

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

 Exceeding duty cycle can

damage unit and void
warranty.

WELD AMPERES

OM-4423 Page 14

600
500

400
300

CV

CC

250
200

150

100

10 15 20 25 30 40 50 60 80 100

% DUTY CYCLE

217 515

4-6. AC Generator Power Curve

240

120

200

100

The ac power curve shows the gen­erator power in amperes.

160
120

80

AC VOLTS

40

0

Notes

80
60

40

20

0

0 20 40 60 80 100 120 140

AC AMPERES IN 110V MODE

0 10203040506070

AC AMPERES IN 220V MODE

220 346−B

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-4423 Page 15

SECTION 5 − INSTALLATION

5

-1. Installing Welding Generator

 Always securely fasten weld-

ing generator onto transport

Movement

OR

Location

OR

OR

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

 Always ground generator

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

 If unit does not have GFCI re-

ceptacles, use GFCI-protected
extension cord.

 See Section 4-2 for lifting eye

rating.

 See Section 5-2 for mounting

information.

Grounding:

1 Equipment Grounding Terminal

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

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

Airflow Clearance

Grounding

GND/PE

18 in

(460 mm)

18 in

(460 mm)

1

18 in

(460 mm)

(460 mm)

2

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

OM-4423 Page 16

install3 6/05 − Ref. 800 652 / Ref. 800 477-A / 803 274

5-2. 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

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 to the base.
Reverse brackets and reattach to
base with original hardware.

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

To Weld Unit In Place:

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

Tools Needed:

9/16 in

2

Welding Unit In Place

Bolting Unit In Place

3

2

4

install3 6/05 803 274 / 200 864-A / 803 562

OM-4423 Page 17

5-3. 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

803 582−B / Ref. 217 358-B

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4423 Page 18

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

3

2

1

4

 Always wear a face shield,

rubber gloves and protective
clothing when working on a
battery.

Remove battery from unit.
5 Vent Caps
6 Sulfuric Acid Electrolyte

(1.265 Specific Gravity)
7 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.

8 Battery Charger

 Read and follow all instruc-

tions supplied with battery

charger.

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

 When electrolyte is low, add

only distilled water to cells to

maintain proper level.

5 A For 30 Minutes

Tools Needed:

30 A For 12 Minutes

5-5. Connecting The Battery

OR

+

−

drybatt1 6/05 − S-0886

 Close door after connecting battery.

Tools Needed:

1/2 in

 Connect Negative (−) Cable Last.

+

−

Ref. 803 576−C / Ref. 217 358-B / S-0756-C

OM-4423 Page 19

5-6. Engine Prestart Checks

Full

Diesel

Full

Check radiator coolant

level when fluid is low in

recovery tank.

Full

Capacity:

6 qt (5.7 L)

Coolant Recovery Tank

Hot Full

Cold 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 10.

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-4423 Page 20

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 and
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-

Ref. 803 576−C

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

Keep radiator and air intake clean and free
of dirt.

 Incorrect engine temperature can

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

 To improve cold weather starting:

Use Preheat switch (see Section 6-2).

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 8-2).

5-7. Connecting To Weld Output Terminals

 Stop engine.

1 Work (−) Weld Output Terminal
2 CV (Wire) Weld Output Terminal
3 CC (Stick/TIG) Weld Output Terminal

 Failure to properly connect weld

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

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

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

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

Stick and TIG Welding

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

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

Use Process/Contactor switch to select type
of weld output (see Section 6-3).

MIG and FCAW Welding

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

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

7

4

5

6

Correct Installation

Do not place

anything between

weld cable terminal

and copper bar.

123

Tools Needed:

3/4 in

Incorrect Installation

Ref 803 843−B / 217 358-B / 803 778-A

OM-4423 Page 21

5-8. Selecting Weld Cable Sizes*

100 ft (30 m) or Less

Weld Output

Terminals

 Stop engine before

connecting to weld out­put terminals.

 Do not use worn, dam-

aged, undersized, or
poorly spliced cables.

Welding

Amperes

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

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

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

10 − 60%

Duty

Cycle

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

Not Exceeding***

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

60 − 100%

Duty

10 − 100% Duty Cycle

Cycle

400 ft

(120 m)

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

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

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

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

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

* This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.

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

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

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

Notes

OM-4423 Page 22

5-9. Connecting To Remote 14 Receptacle RC14

24 VOLTS AC

OUTPUT

Socket* Socket Information

A 24 volts ac. Protected by circuit

breaker CB8.

24 VOLTS AC

B Contact closure to A completes

24 volt ac contactor control
circuit.

C Output to remote control:+10

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

*The remaining sockets are not used.

Notes

OR

Ref 803 576−C

REMOTE

CONTROL

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.

Current feedback: 1 volt per

F

100 amperes.

H Voltage feedback: 1 volt per 10

arc volts.

K Chassis common.

volt ac circuit.

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4423 Page 23

SECTION 6 − OPERATING WELDING GENERATOR

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

1 25467 8910

OM-4423 Page 24

3

Stop

217 358-B / 803 576−C

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

Engine Starting Controls

1 Preheat Switch
Use switch to energize starting aid for cold

weather starting (see starting instructions fol­lowing).

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

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

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

3 Engine Stop Lever
Use lever to stop engine if Engine Control

switch does not work.

 The Engine Stop lever shuts off the fuel

supply. However, the Engine Stop lever
will not stop the engine if the engine can
draw fuel-rich air from the surrounding
atmosphere (oil refineries).

To Start:

 Do not use ether.

 If engine does not start, let engine come

to a complete stop before attempting re­start.

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

Below 325 F (05 C): turn engine control switch
to Auto position. Push Preheat switch up for
60 seconds. Turn Engine Control switch to
Start. Release Engine Control switch and
Preheat switch when engine starts.

To Stop: turn Engine Control switch to Off
position.

Engine Gauges, Meters, And Lights

4 Fuel Gauge/Hourmeter
Use gauge to check fuel level or total engine

operating hours.
To check fuel level or engine hours when en-

gine is not running, turn Engine Control switch
to Run or Auto (optional) position.

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

perature exceeds 230° F (110° C) or engine
oil pressure is below 10 psi (69 kPa).

 Normal engine temperature is 180 - 203

F (82 - 95 C). Normal oil pressure is 30

- 60 psi (207 - 414 kPa).

 Do not run engine until trouble is

fixed.

Weld Controls

6 Remote Control Receptacle
Use receptacle to connect remote controls,

wire feeders, and tools.
When a remote control is connected to the

Remote receptacle, the Auto Sense Remote
feature automatically switches voltage/am­perage control to the remote control (see Sec­tion 5-9).

With remote control connected, weld output is
determined by a combination of front panel
and remote control voltage/amperage set­tings.

If no remote control is connected to the Re­mote receptacle, the front panel Voltage/Am­perage control adjusts voltage and amper­age.

 If a remote device connected to Remote

Receptacle RC14 is faulty or is discon­nected, the meters display Help 25 (see
Section 8-10). Clear fault by stopping
and restarting the unit or by turning Pro­cess/Contactor switch to another posi­tion.

7 Process/Contactor Switch
See Section 6-3 for Process/Contactor

switch information.
8 Voltage/Amperage Control
With Process/Contactor switch in any Stick or

TIG setting, use control to adjust amperage.
With Process/Contactor switch in any Wire
(MIG) position, use control to adjust voltage.
With Voltage/Amperage Adjust Switch in Re­mote position, control limits the remote am­perage in Stick or TIG mode, but has no effect
in Wire (MIG) modes.

Weld Meters

 Weld meters also work in combination to

display troubleshooting help codes (see
Section 8-10).

9 DC Voltmeter
Voltmeter displays preset voltage (MIG weld-

ing) with contactor off, and actual output volt­age with the contactor on. Voltmeter displays
voltage at the weld output terminals, but not
necessarily the welding arc due to resistance
of cable and connections.

To set voltage, turn contactor off and turn Pro­cess/Contactor switch to Wire position. Turn
V/A control until desired voltage is displayed
on Voltmeter. When welding is finished, volt­meter displays weld voltage and then defaults
to preset voltage.

10 DC Ammeter
Ammeter displays preset amperage (Stick

and TIG only) when not welding, and actual
output amperage when welding.

To set amperage, turn Process/Contactor
switch to Stick or TIG position. Turn V/A con­trol until desired amperage is displayed on
Ammeter. When welding is finished, ammeter
displays weld amperage and then defaults to
preset amperage.

OM-4423 Page 25

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

1

1 Process/Contactor Switch

 Weld output terminals are ener-

gized when Process/Contactor
switch is in a Weld Terminals Al­ways On position and the engine
is running.

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

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

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

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

When switch is in Stick mode, select one
of four arc drive (dig) settings to provide
additional amperage during low voltage
(short arc length) conditions and prevent
“sticking” electrodes. Turn control from A
to D to increase arc drive (dig) from min
to max.

Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 6-4).

Ref. 803 576−C / 217 358−B

Process/Contactor Switch Settings

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

Remote On/Off Switch Re-

quired −TIG HF Required Or

Scratch Start

Remote On/Off Switch

Required − Stick

Remote On/Off Switch
Required − CV Feeder

Using 24 Volt Remote

Weld Terminals Always On −

Wire

Weld Terminals Always On −

Stick

Weld Terminals Always On −

TIG Lift-Arc

GTAW With HF Unit, Pulsing

Device, Or Remote Control

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

MIG (GMAW)

w/Constant Speed Feeder

MIG (GMAW)

w/Voltage Sensing Feeder

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting

And Gouging

TIG Lift-Arc (GTAW) Electrode Hot Active

At Remote 14 Receptacle Active

At Remote 14 Receptacle Active

Electrode Hot Active

Electrode Hot Active

OM-4423 Page 26

6-4. Lift-Arc™ Start Procedure

Lift-Arc Start Method

“Touch”

Do NOT Strike Like A Match!

1

1 − 2

Seconds

Lift-Arc  TIG

With Lift-Arc TIG selected, start
arc as follows:

1 TIG Electrode
2 Workpiece

2

Turn gas on. Touch tungsten
electrode to workpiece at weld start
point. Hold electrode to
workpiece for 1-2 seconds, and
slowly lift electrode. Arc is formed
when electrode is lifted.

Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece
without overheating, sticking, or be­ing contaminated.

Application:

Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to
replace the scratch method.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4423 Page 27

6-5. Remote Voltage/Amperage Control

1

1 Remote 14 Receptacle RC14
Connect optional remote control to RC14 (see

Section 5-9).

 When a remote control is connected to the

Remote receptacle, the Auto Sense Re­mote feature automatically switches volt­age/amperage control to the remote con­trol. When a device is connected to the Re­mote receptacle, remote voltage/amper­age control is always available regardless
of the position of the Process/Contactor
switch.

Connect Remote

Control To Remote

Receptacle RC14

Connect Remote

Control To Remote

Receptacle RC14

Set TIG or STICK Process

Set WIRE Process

Adjust Optional Remote

Control to 100%

In Example:

Process = Remote Stick

Min = 20 A DC

Max = 205 A DC

Adjust Optional Remote

Control To Desired Weld

Output

Set V/A Control

To Desired Maximum

Weld Output Using Weld

Meters

Max (205 A DC)

Min (20 A DC)

Adjust Optional Remote Control

Weld meters will always

show the combined main and

remote control setting and
machine welds at nominal

output settings of the meter.

Weld meters show preset

output when not welding.

OM-4423 Page 28

0774 / Ref. 217 358-B / Ref. 803 576−C

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. 110 Volt Receptacles

3

2

4

1

1 110/55V 32 A AC Receptalce RC11
2 110/55V 16A AC Receptacle RC12
Receptacles RC11 and RC12 supply 60 Hz

single-phase power at weld/power speed.
Maximum output from RC11 is 3.5 kVA/kW.

Maximum output from RC12 is 1.8 kVa/kW.
Maximum combined output of RC11 and

RC 12 is 4.4 kVa/kW.
3 Circuit Breaker CB6

4 Circuit Breaker CB5

CB6 protects RC12 from overload. If a cir­cuit breaker opens, the receptacle does not
work. Press button to reset breaker.

Circuit breaker CB5 protects receptacle
RC11 and the generator winding from over­load. If CB5 opens, the receptacles do not
work. Place CB5 switch in On position to
reset circuit breaker.

Ref. 217 358-B

 If a circuit breaker continues to open,

contact Factory Authorized Service
Agent.

 Generator power decreases as weld

output increases.

OM-4423 Page 29

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

 Stop engine before maintaining.

Recycle engine

fluids.

 See Engine Manual and Maintenance Label

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

Every

8

Hours

Every

50

Hours

Every

100

Hours

Every

250

Hours

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

FUEL

WATER

 Fuel/Water Separator  Fuel Level  Oil Level  Oil, Fuel Spills

 Coolant Level

 Air Cleaner Element  Weld Terminals

 Battery Terminals  Air Cleaner Hoses

1/2 in.

(13 mm)

Reference

Section 5-6,
8-7

Section 8-3

Engine
Manual,
Section 8-4,
8-7

 Unreadable Labels  Fan Belt Tension  Oil  Oil Filter Spark Arrestor

Every

500

Hours

 Weld Cables Radiator Fluid Level  FuelFilter  Drain Sludge

Every

1000

Hours

 Slip Rings*
 Brushes*

Every

2000

Hours

 Injectors*

OM-4423 Page 30

OR

Valve Clearance*  Inside Unit

SLUDGE

FUEL

Section 5-6,
8-7

Section 8-9
and Engine
Manual

8-2. Maintenance Label

5 5

5 5

5 5

OM-4423 Page 31

8-3. Servicing Air Cleaner

Keep nozzle

2 in (51 mm)

from element.

Blow Inspect

Optional

 Stop engine.
 Do not run engine without air

2

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 it has holes or damaged gaskets.

Reinstall primary element and cap (dust
ejector down).

OM-4423 Page 32

aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 217 358-B

8-4. Inspecting And Cleaning Spark Arrestor Muffler

3

1

2

 Stop engine and let cool.

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

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

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

 Stop engine and let cool.

Reinstall cleanout plug.

Tools Needed:

3/8 in

8-5. Servicing Engine Cooling System

2

803 582 / Ref. 217 358-B

 Stop engine and let cool.

1 Radiator Draincock
2 Radiator Cap Cover
Change coolant according to engine

manual. Add coolant according to Sec­tion 5-6).

Run engine until engine reaches normal
operating temperature. Check coolant
level in recovery tank. Add coolant if nec­essary.

After engine cools, check coolant level
again and add coolant if necessary.

1

803 576−B / Ref. 217 358−C

OM-4423 Page 33

8-6. Adjusting Engine Speed On Standard Models

Engine Speed

(No Load)

Weld/Power

RPM (Hz)

1880 (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.
Place Process/Arc Drive (Dig)

Control in Stick 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.

1

2

Stop

OM-4423 Page 34

Tools Needed:

Ref. 803 576−C

8-7. Servicing Fuel And Lubrication Systems

6

2

4

5

3

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

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

1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary (Canister) Fuel Filter

5 Secondary (In-Line) Fuel

Filter

6 Fuel Tank Sludge Drain Valve

To change oil and filter:

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

To replace primary (canister) 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.

Inspect fuel lines, and replace if
cracked or worn.

To drain water from fuel system:

See engine manual.

To replace secondary (in-line)
fuel filter:

Note direction of fuel flow as indi­cated by arrow on side of filter. Re­move fuel line clamps and discon­nect fuel lines from fuel filter. Re­place filter, reconnect fuel lines, and
reinstall clamps.

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

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

 Properly lift unit and secure

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

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

Close door.

Tools Needed:

1

Ref. 217−358−B / 802 490 / 803 576−C

OM-4423 Page 35

8-8. Overload Protection

 Stop engine.

 When a circuit breaker or fuse

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

1 Fuse F1
F1 protects the stator exciter wind-

ing from overload. If F1 opens, weld
and generator power is low or stops
entirely.

2 Circuit Breaker CB1 (Not

Shown)
3 Circuit Breaker CB2
4 Circuit Breaker CB3

5 Circuit Breaker CB8
CB1 protects the engine battery cir-

cuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
when the fault is corrected.

CB2 protects the engine wiring har­ness. If CB2 opens, the engine will
not crank.

CB3 protects part of the weld control
wiring harness. If CB3 opens, weld
and generator power output stops.

CB8 protects the 24 volt ac output to

1

remote receptacle RC14. If CB8
opens, 24 volt output to RC14 stops.

Press button to reset breaker.

3

4

5

OM-4423 Page 36

Ref. 217 358−B / 803 580 / 803 576−C

8-9. Checking Generator Brushes

Damaged Brushes

5/16 in. (8 mm)

Minimum Length

Replace

9/16 in. (14.3 mm)

New Length

1

 Stop engine and let cool.

1 Generator Brush With Spring
Mark and disconnect leads at brush hold-

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

material is at or near minimum length.

Ref 2114 778−D / S−0233−A

Notes

MATERIAL THICKNESS REFERENCE CHART

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

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

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

OM-4423 Page 37

8-10. Voltmeter/Ammeter Help Displays

1

HL.P

2

HL.P

3

HL.P

4

HL.P

5

HL.P

6

HL.P

20

21

22

23

24

25

Use the Voltmeter/Ammeter help
displays to diagnose and correct
fault conditions.

 When a help code is displayed

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

 To reset help displays, stop

unit and then restart. See item
6 below to reset Help 25 dis­play.

1 Help 20 Display
Indicates a failure of meter display

module PC2, or the wiring between
PC2 and main control module PC1.
If this display is shown, have Facto­ry Authorized Service Agent check
PC1, PC2, and the wiring between
PC1 and PC2.

2 Help 21 Display
Indicates thermistor TH1 on the

main rectifier heat sink has failed.
If this display is shown, have Facto­ry Authorized Service Agent check
TH1., and the wiring between TH1
and PC1.

3 Help 22 Display
Indicates the rectifier heat sink has

overheated. If this display is shown,
check generator cooling system
and/or reduce duty cycle. Keep en­gine access door closed when run­ning to maintain proper cooling air
flow past rectifier. Allow unit to cool
before restarting. If problem contin­ues, have Factory Authorized Ser­vice Agent check unit.

4 Help 23 Display
Indicates one of the rectifier output

SCR’s has failed. If this display is
shown, have Factory Authorized
Service Agent check the rectifier
SCR’s.

5 Help 24 Display
Indicates weld open circuit voltage

(OCV) is too high (above 41 volts
dc). If this display is shown, have
Factory Authorized Service Agent
check main control module PC1.

6 Help 25 Display
Indicates a remote device con-

nected to Remote Receptacle
RC14 may be faulty. Help 25 is also
displayed whenever a remote de­vice has been connected to RC14
and then disconnected. Clear fault
by stopping and restarting the unit
or by turning Process/Contactor
switch to another position. If prob­lem continues, have Factory Autho­rized Service Agent check the re­mote device, filter board PC6, and
main control module PC1.

OM-4423 Page 38

Ref. 803 576−C / 217 358-B

8-11. Troubleshooting

Note

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

A. Welding

Trouble Remedy

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

No weld output, or generator power out­put at ac receptacles.

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

Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
On/Off Switch Required position and turn remote contactor on (see Section 6-3).

Reset circuit breaker CB8 (see Section 8-8). Check for faulty remote device connected to RC14.

Check and secure connections to Remote Control receptacle RC14 (see Section 5-9).

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

Disconnect equipment from generator power receptacles during start-up.

Reset circuit breaker CB3. (see Section 8-8).

Check fuse F1, and replace if open (see Section 8-8). If F1 is open, have Factory Authorized Service
Agent check the voltage regulator module PC3.

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

Have Factory Authorized Service Agent check brushes and slip rings, voltage regulator module PC3, 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. Have Factory Authorized Service Agent check main control module PC1 and hall device HD1.

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

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

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

Have Factory Authorized Service Agent check main control module PC1, voltage regulator module PC3,
and main rectifier.

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

Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 5-9).

No 24 volt ac output at Remote recep­tacle RC14.

Reset circuit breaker CB8 (24 volt) (see Section 8-8).

B. 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.

Reset receptacle circuit breakers (see Section 7-1).

OM-4423 Page 39

Trouble Remedy

Check fuse F1, and replace if open (see Section 8-8). Have Factory Authorized Service Agent check vol­tage regulator module PC3.

Reset circuit breaker CB3 (see Section 8-8).

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

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

High output at generator power ac re­ceptacles.

Low output at generator power ac recep­tacles.

Have Factory Authorized Service Agent check voltage regulator module PC3.

Check engine speed, and adjust if necessary.

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

C. Engine

Trouble Remedy

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

Check battery connections and tighten if necessary.

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

Reset circuit breaker CB2 (see Section 8-8).

Check engine wiring harness plug connections.

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

Engine cranks but does not start. Check fuel level.

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

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

Air in fuel system. See engine manual.

Engine hard to start in cold weather. Use Preheat switch S4 (see Section 6-2).

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

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

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

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

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

Engine slowly stopped and cannot be
restarted.

temperature is too high (see Section 5-6 ).

Reset circuit breaker CB1 and/or CB2 (see Section 8-8). Have Factory Authorized Service Agent
check engine alternator, engine harness, fuel solenoid FS1, and the fuel pump.

Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, inte­grated rectifier SR2, fuel solenoid FS1, and the fuel pump.

See engine manual.

Check fuel level.

Check engine air and fuel filters (see Sections 8-3 and 8-7).

See engine manual.

OM-4423 Page 40

Trouble Remedy

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

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

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months).

Engine idles, but does not come up to
weld speed (units with idle option only).

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

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

Have Factory Authorized Service Agent check idle module PC5 and current transformer CT1.

Check for obstructed throttle solenoid.

Check for obstructed throttle solenoid.

Have Factory Authorized Service Agent check idle module PC5, and control relay CR4.

Dry engine according to run-in procedure (see Section 10).

OM-4423 Page 41

SECTION 9 − ELECTRICAL DIAGRAMS

OM-4423 Page 42

Figure 9-1. Circuit Diagram For Welding Generator

221 499-B

OM-4423 Page 43

10-1. Wetstacking

1

SECTION 10 − RUN-IN PROCEDURE

 Do not perform run-in

procedure at less than 20
volts weld output and do not
exceed duty cycle or equip­ment damage may occur.

1 Welding Generator

2

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

 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 8/01

OM-4423 Page 44

10-2. 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 not
exceed duty cycle or equip­ment damage may occur.

1 Load Bank
Turn all load bank switches Off. If

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

2 Welding Generator
Place V/A control in minimum posi-

tion, 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-4423 Page 45

10-3. 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 not
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 V/A 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-4423 Page 46

S-0684

SECTION 11 − GENERATOR POWER GUIDELINES

NOTE

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

11-1. Selecting Equipment

1

1 Generator Power Receptacles

− 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 in­sulated.

2

3

OR

11-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

2

Be sure equipment
has this symbol
and/or wording.

3

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

 Always ground generator

frame to vehicle frame to pre­vent 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 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.

S-0854

OM-4423 Page 47

11-3. 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.

11-4. 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 11-8).

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

OM-4423 Page 48

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

11-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

1/6 HP 1225 500
1/4 HP 1600 600
1/3 HP 2100 700
1/2 HP 3175 875

Capacitor Start-Induction Run 1/3 HP 2020 720

1/2 HP 3075 975
3/4 HP 4500 1400

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800

Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

1/6 HP 1400 550
1/4 HP 1850 650
1/3 HP 2400 800
1/2 HP 3500 1100

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

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000
Grain Cleaner 1/4 HP 1650 650
Portable Conveyor 1/2 HP 3400 1000
Grain Elevator 3/4 HP 4400 1400
Milk Cooler 2900 1100
Milker (Vacuum Pump) 2 HP 10500 2800
FARM DUTY MOTORS 1/3 HP 1720 720
Std. (e.g. Conveyors, 1/2 HP 2575 975
Feed Augers, Air 3/4 HP 4500 1400
Compressors) 1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850
3 HP 15900 3900

5 HP 23300 6800
High Torque (e.g. Barn 1-1/2 HP 8100 2000
Cleaners, Silo Unloaders, 5 HP 23300 6000
Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000

10 HP 46700 10700
3-1/2 cu. ft. Mixer 1/2 HP 3300 1000
High Pressure 1.8 Gal/Min 500 PSI 3150 950
Washer 2 gal/min 550 PSI 4500 1400
2 gal/min 700 PSI 6100 1600
Refrigerator or Freezer 3100 800
Shallow Well Pump 1/3 HP 2150 750

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

OM-4423 Page 49

11-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

3/8 in 400 400
1/2 in 600 600

Circular Saw 6-1/2 in 500 500

7-1/4 in 900 900
8-1/4 in 1400 1400

Table Saw 9 in 4500 1500

10 in 6300 1800
Band Saw 14 in 2500 1100
Bench Grinder 6 in 1720 720

8 in 3900 1400

10 in 5200 1600
Air Compressor 1/2 HP 3000 1000

1 HP 6000 1500

1-1/2 HP 8200 2200

2 HP 10500 2800
Electric Chain Saw 1-1/2 HP, 12 in 1100 1100

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

Heavy Duty 12 in 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in 400 400
Flood Lights HID 125 100

Metal Halide 313 250

Mercury 1000

Sodium 1400

Vapor 1250 1000
Submersible Pump 400 gph 600 200
Centrifugal Pump 900 gph 900 500
Floor Polisher 3/4 HP, 16 in 4500 1400

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900

2-1/2 HP 1300 1300

OM-4423 Page 50

11-8. Power Required To Start Motor

4
1

VOLTS AMPS

3

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GHJ KLMNP

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

11-9. How Much Power Can Generator Supply?

1

2

1 Limit Load To 90% Of

Generator Output

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

2 5 Second Rule
If motor does not start within 5

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

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

OM-4423 Page 51

11-10. 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 produce enough output to meet all
requirements, connect only essential loads
(pumps, freezers, heaters, etc. − See Sec­tion 11-4).

OM-4423 Page 52

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

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

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

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

Current

(Amperes)

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

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

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

15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)

20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)

25 3000 175 (53) 112 (34) 62 (19) 37 (11)

30 3600 150 (46) 87 (26) 50 (15) 37 (11)

35 4200 125 (38) 75 (23) 50 (15)

40 4800 112 (34) 62 (19) 37 (11)

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

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

Load (Watts) 4 6 8 10 12 14

Current

(Amperes)

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

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

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

15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)

20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)

25 6000 350 (107) 225 (69) 125 (38) 75 (23)

30 7000 300 (91) 175 (53) 100 (31) 75 (23)

35 8400 250 (76) 150 (46) 100 (31)

40 9600 225 (69) 125 (38) 75 (23)

45 10,800 200 (61) 125 (38)

50 12,000 175 (53) 100 (31)

*Conductor size is based on maximum 2% voltage drop

Load (Watts) 4 6 8 10 12 14

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

OM-4423 Page 53

 Hardware is common and not

available unless listed.

Wirng harnesses are listed at
the end of parts section.

SECTION 12 − PARTS LIST

8

9

10

11

12

13

7

3−Fig.12−5

1−Fig.12−3

2

96−Fig.12−2

104

6

4

103

98

97

5

102

94

101

1009918

88

92

93

17

87

19

90

89

86

85

84

20

16

15

14

21

22

23

24

25

91

83

82

81

80

79

OM-4423 Page 54

95

Figure 12-1. Main Assembly

28

30

31

78

77

71−Fig.12−4

76

75

74

70

73

69

26

72

27

68

29

55

67

65

64

66

33

60

58

57

55

59

34

56

36

63

32

61

37

62

35

38

39

46

45

47

48

40

44

49

50

41

32

42

43

51

45

52

53

54

803 830−D

OM-4423 Page 55

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-1. Main Assembly

1 Figure 12-3 Control Panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 217070 Bracket, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Figure 12-5 Rectifier Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 214742 Capacitor Assy (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213489 Bus Bar, Capacitor Bank Negative 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213490 Bus Bar, Capacitor Bank Positive 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C10 163535 Capacitor, Elctlt 16000 Uf 60 Vdc Can 1.75 Dia 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181853 Insulator, Screw (For Rectifier Mtg) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Z1 213929 Stabilizer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192303 Angle, Mtg Stabilizer 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 215522 Bracket, Vault 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 +213488 Panel, Engine Side 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 PC1 220739 Module, Main Control/Scr Gating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PC3 214770 Module, Voltage Regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 213493 Upright, Center Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 189464 Seal, Weather Lift Eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 213501 Bracket, Fuel Pump/Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 Bracket, Fuel Filter Mtg. (Order Thru Engine Manufacturer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 218469 Filter, Fuel Spin−on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 207721 Pump, Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 *213858 Filter, Fuel In−line 5/16x5/16 Mic 125 −175 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 214753 Bracket, Holddown Fuel Tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 213602 Gasket, Exhaust Outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 212620 Pipe, Exhaust Flexible Inlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 183314 Clamp, Muffler 1.625 Dia U Pld 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 212604 Baffle, Air Lower Radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 201528 Muffler, Exhaust Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 213580 Pipe, Exhaust Spark Arrestor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 088528 Spark Arretsor, Exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 201399 Pipe, Exhaust Extension 5.0” Long 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 +213470 Cover, Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049525 Nut, 312−18 U−nut Multi−thread 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 189052 Grommet, Plastic Neck Filler Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 190198 Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 222513 Label, Warning Falling Equipment Can Cause Serious 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 201851 Cover, Radiator Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 214604 Pipe, Exhaust Elbow 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 224265 Label, Warning Hot Exhaust Parts Do Not Touch 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 192041 Label, Use Diesel Fuel Only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 213472 Keeper, Latch Engine Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 213471 Bracket, Cover Top 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 212624 Baffle, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 213503 Guard, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 +212607 Shroud, Radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 212606 Radiator, W/14# Cap 3 Row Core 1.25 In Inlet/Outlet (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

40 212603 Baffle, Air Upper Radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 +220954 Upright, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 220295 Bracket, Stiffener 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 190190 Tank, Coolant Recovery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 213502 Guard, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 225120 Label, Warning Moving Parts Can Cause Injury 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 217698 Label, Help Codes 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 168385 Label, Warning Battery Explosion Can Blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 203260 Label, Caution Do Not Use Ether 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 215269 Label, Diesel Engine Maintenance Kubota V1505 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 199592 Latch, Paddle Series 20 (Black) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 +213487 Door, Engine Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-4423 Page 56

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-1. Main Assembly (Continued)

191626 Bumper, Door Engine Access 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 189975 Hinge, Door Access 180 Deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 087341 Bumper, Door 1.000 Od X .750 High Rbr 50 Duro W/O 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 213486 Panel, Rocker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 213266 Mount, Engine/Generator Flange Mtg 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 197506 Screw, M14−1.5x 30 Hex Hd−pln 8.8 Pln 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 213480 Bracket, Mtg Engine 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 049026 Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 083883 Washer, Lock .402idx0.709odx.087t Stl Split10mm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199505 Hose Assy, Oil Drain 32.000 Lg (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 113854 Hose, Sae .500 Id X .780 Od Xcoil 2.6 Ft.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 176529 Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 165271 Valve, Oil Drain 3/8−18 Nptf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 212616 Hose, Radiator Lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 218468 Belt, Alternator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 210790 Engine, Kubota Dsl Elec V1505 (1800) (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*218467 Filter, Oil Kubota V1505 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213244 Switch, Coolant Temp N.C. 230f 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 212615 Hose, Radiator Upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 216811 Clip, Nut Retaining 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 197613 Air Cleaner, Intake 5.250 In (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197675 Dust Ejector, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*197676 Element, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197677 Cover Assy, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197678 Body, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦*197679 Element, Air Cleaner Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197829 Bracket, Mtg Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 212618 Hose, Air Intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 221485 Switch,Pressure Oil 4psi No 1/8−28 Bspt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 Figure 12-4 Generator Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 213461 Bracket, Mtg Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212623 Tank, Fuel (Includes Fuel Cap And Items Below) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 189908 Valve, Drain Fuel 180 Deg Zinc Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 181572 Bushing, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 124253 Bushing, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 212611 Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 212610 Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 SENDER 213265 Sender, Fuel Gauge 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172071 Clamp, Hose .520 − .605 Clp Dia Slfttng Black 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211961 Hose, Sae .312 Id X .560 Od X 16.000 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213804 Hose, Sae .312 Id X .560 Od X 2.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

191819 Hose, Sae .312 Id X .560 Od X 15.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145054 Hose, Sae .187 Id X .410 Od X 26.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 213465 Bolt, J Stl .312−18 X 7.250 Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 213466 Bracket, Battery Holddown 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 BATT 111352 Battery, Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 190207 Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190206 Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 213668 Bracket, Mtg Unit 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 224266 Label, Warning Do Not Weld On Base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 213458 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 213460 Crossmember, Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 213463 Spacer/Snubber, Generator Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 213462 Pad, Mtg Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 213459 Crossmember, Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213670 Screw, 500−13x2.25 Hex Flange−hd Gr8 Pln Chem/Phys 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

071731 Washer, Flat .656idx2.250odx.187t Stl Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-4423 Page 57

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-1. Main Assembly (Continued)

213600 Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

071731 Washer, Flat .656idx2.250odx.187t Stl Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213464 Bracket, Battery Locator (In Base − Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 213485 Support, Engine Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91 213484 Support, Engine Rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 200865 Label, Ce Sound Power Level 98db 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 +220953 Upright, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 223379 Label, Warning General Precautionary CSA 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 220955 Panel, Front Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96 Figure 12-2 Front Panel Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 218449 Label, Rating Card Code 154 (Provide Serial No. When Ordering) 1. . . . . . . . . . . . . . . . . . . . . . . .

98 173216 Label, Ce European Community Mark 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 213504 Tray, Reactor & Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213491 Insulator, Capacitor Bank (Applies To Reactor /Rectifier Tray) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 213500 Brkt, Beam Support 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 T1 220887 Xfmr, Isolation 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 TE1 172661 Block, Stud Connection 6 Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 R3 213027 Resistor, WW Tap 300 W 40 Ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

173734 Link, Jumper 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213506 Bracket, Hold−Down Fuel Tank (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215329 Kit, Label (Includes Safety And Informational Labels) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

label individually or as part of Label Kit 215 329.

* Recommended Spare Parts.
♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4423 Page 58

 Hardware is common and not

available unless listed.

Wirng harnesses are listed at
the end of parts section.

13

11

12

14

15

17

16

18

23

22

21

20

19

30

29

24

25

26

27

28

10

8

7

6

5

4

3

1

2

37

36

9

35

31

34

32

33

Figure 12-2. Panel, Front w/Components

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 96 )

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

2 072590 Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 170391 Conn, Circ Ms Protective Cap Size 20 Nylon 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 190323 Boot, Circuit Breaker Clear Hex Nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 097922 Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Nameplate, Control (Order By Model & Serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PC6 217008 Circuit Card Assy, Connector/Receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CB8 083432 Circuit Breaker, Man Reset 1p 10a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 213655 Panel, Front Engine/Weld Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

803 831−A

Quantity

OM-4423 Page 59

Item

No.

Dia.

Mkgs.

Part

No.

Description

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

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

11 134201 Stand−off Support, Pc Card .312/.375w/Post&lock .43 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 PC2 214660 Circuit Card Assy, Display W/Program 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 R1 214760 Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 R2 193118 Pot, Cp Flat 1t 2. W 1k Ohm Linear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 S4 021467 Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 S1 212436 Switch, Ignition 4 Position (Includes Knob) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 039047 Terminal, Pwr Output Red 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 010381 Connector, Rectifier 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 C13, 14, 15 128750 Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 RC12 173555 Rcpt, Str 2p3w 16a 130v Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 CB6 201083 Circuit Breaker,Man Reset 2p 20a 250vac 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 Nameplate, Generator Power (Order By Model & Serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 213478 Panel, Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 C11, C12 217054 Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 CB5 222187 Circuit Breaker, Man Reset 2p 35a 240vac Screw-90 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 GRD 083030 Stud, Brs .250−20 X 1.750 W/Hex Collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 010915 Washer, Flat .257idx0.640odx.031t Brs 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 601836 Nut, 250−20 .50hex .19h Brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 RC11 173556 Rcpt,Str 2p3w 32a 130v Flange Mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 209056 Cover, Receptacle W/Gasket 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 Nameplate, Weld Terminal (Order By Model & Serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 181169 Spacer, Output Stud 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 186621 Boot, Generic Output Stud 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 180735 Washer, Output Stud 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 039046 Terminal, Pwr Output Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 FUEL/HM 214768 Gauge, Fuel Elec/Hour Meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 021385 Boot, Toggle Switch Lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

♦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 215 329

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-4423 Page 60

 Hardware is common and not

available unless listed.

Wirng harnesses are listed at
the end of parts section.

2

1

4

3

5

6

7

9

10

Figure 12-3. Control Panel

Item

No.

Dia.

Mkgs.

Part

No.

Description

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

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

2 129524 Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CB1 190374 Circuit Breaker, Auto Reset 12vdc 40 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 CR1 223710 Relay, Encl 12vdc Dpst−no 25a 6pin Flange 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 046432 Holder, Fuse Mintr .250 X 1.250 Panel Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 F1 085874 Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 CR2 090104 Relay,Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CR3 197325 Relay, Encl 12vdc Spst 70a 4pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 SR1, SR2 035704 Rectifier, Integ Bridge 40. Amp 800v 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CB2, CB3 083432 Circuit Breaker, Man Reset 1p 10a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

803 798−D

Quantity

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

label individually or as part of Label Kit 215 329

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-4423 Page 61

 Hardware is common and not

available unless listed.

Wirng harnesses are listed at
the end of parts section.

13

12

14

5

4

3

1

2

8

9

10

11

6

7

1920181517

16

803 857−A

Figure 12-4. Generator

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-4. Generator (Figure 12-1 Item 70)

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

2 053390 Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 192600 Fan, Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 159918 Baffle, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 193515 Adapter, Engine Machined Cat 3013c 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 602211 Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 192686 Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 602211 Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 192686 Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 212641 Stud, Stl .375−16 1.625x 19.000 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 STATOR 219920 Stator, Generator 4 Pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 160943 Endbell 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 167788 Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 218552 Brush, Assembly 2 Pole (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 047879 Bar, Retaining Brushholder 2 Brushes 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 161306 Cap, Brushholder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 126984 Brush w/Spring 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 005614 Holder, Brush 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 125548 Holder, Brush Elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 158832 Screw, 010−32x .50 Hex Hd−slt Stl Pld Sq Cone Sems 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

label individually or as part of Label Kit 215 329.

*Recommended Spare Parts.
♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4423 Page 62

 Hardware is common and not

available unless listed.

Wirng harnesses are listed at
the end of parts section.

10

8

6

1

3

2

7

5

4

9

Figure 12-5. Rectifier Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-5. Rectifier Assembly (Figure 12-1 Item 3)

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

1 211984 Heat Sink 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 MOD1,2,3 218296 Kit, Module SCR 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 MOD4,5,6 218292 Kit, Module SCR 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 212602 Bus Bar, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 212639 Bus Bar, Rectifier 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 212601 Insulator, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 TH1 213930 Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8C1−6 215611 Capacitor Assy 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 C7,8,9 048420 Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 217085 Bus Bar, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181853 Insulator, Screw (For Mounting Rectifier) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

803 685-A

Quantity

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-4423 Page 63

Note

Some wiring harness components (switches, relays, circuit breakers) are also referenced
elsewhere in this parts list. Purchase components separately or as part of the associated
wiring harness.

Item

No.

Dia.

Mkgs.

S4 021467 Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SR1, SR2 035704 Rectifier, Integ Bridge 40. Amp 800v 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB1 190374 Circuit Breaker, Auto Reset 12vdc 40 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB2, CB3 083432 Circuit Breaker, Man Reset 1p 10a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR3 197325 Relay, Encl 12vdc Spst 70a 4pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 214932 Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For S1 211292 Conn, Pack 4p 1row Female 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For S1 211293 Conn, Pack Terminal Position Assurance(Lock) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG2 150316 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG9 214951 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8 147992 Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 193184 Conn, Rect Cinch 30 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG7 193183 Conn, Rect Cinch 18 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG9 215261 Conn, Deutsch 12p 2row Female Plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 215262 Conn, Deutsch 12p 2row Female Plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG5 113750 Conn, Rect Mini 045 4skt 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part

No.

Wiring Harnesses

217113 Harness, Engine Kubota (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148850 Socket, Relay 5 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212116 Conn, Deutsch 2p 1row Female Plug 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212117 Conn, Deutsch Wedge Lock 2 Position 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214933 Seal, Wire Univ 039 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214934 Seal, Plug Univ 039 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

129524 Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

221864 Harness, Weld Control CE (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214933 Seal, Wire Univ 039 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214934 Seal, Plug Univ 039 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215265 Conn, Deutsch Wedge Lock 12 Position 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215343 Seal, Plug Deutsch 12−16 Size 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217000 Cable, Lem 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215340 Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214933 Seal, Wire Univ 039 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description

Quantity

PLG11 193183 Conn, Rect Cinch 18 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4423 Page 64

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

207716 Conn, Faston Mini Polarized 2 Skt G1k1 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

207718 Conn, Faston Mini Polarized 2 Skt G2k2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217010 Harness, Receptacle Auxiliary Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

Your distributor also gives
you ...

Service

You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

Effective January 1, 2005

(Equipment with a serial number preface of “LF” 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 Sources (Unless Otherwise Stated)

* Water Coolant Systems (Integrated)

* 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 and Coolers
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Maxstar 85, 140
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* 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 Bobcat,
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 based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.

miller_warr 1/05

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois 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:

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05