Miller Electric Big Blue 402D, Big Blue 602DR, Big Blue 502D User Manual

OM-495 192 774AR

October 2003

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 402D, 502D, 602D

Visit our website at

www.MillerWelds.com

And Non-CE Models

From Miller to You

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

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

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

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

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

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

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

Working as hard as you do

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

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

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

Mil_Thank 7/03

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3-1. Warning Label Definitions (For Wordless Labels) 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Manufacturer’s Rating Labels For Non-CE Products 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Manufacturer’s Rating Labels For CE Products 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Symbols And Definitions 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Weld, Power, And Engine Specifications 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Dimensions, Weights, And Operating Angles 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Volt-Ampere Curves For CC Models 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Volt-Ampere Curves For CC/CV Models 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Fuel Consumption 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Duty Cycle And Overheating 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. AC Generator Power Curve 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Optional Three-Phase Generator Curves 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator (See Sections 5-2 And 5-3) 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Using Lifting Eye 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Mounting Welding Generator 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Installing Exhaust Pipe 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Installing Engine Side Baffle (CE Models Only) 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Activating The Dry Charge Battery (If Applicable) 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Connecting The Battery 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Installing Optional Ether Cylinder (Deutz F3L912 Engine Only) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Engine Prestart Checks 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Connecting To Weld Output Terminals 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Selecting Weld Cable Sizes* 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-12. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 32 . . . . . . . . . . . . . . . . . . . . .

5-13. Connecting To Remote 14 Receptacle RC14 On CC/CV Models 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Front Panel Controls For CC Models (See Section 6-2) 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) 35 . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Remote Amperage Control On CC Models (Optional) 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Weld Control/Arc Condition Information Label 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Front Panel Controls For CC/CV Models (See Section 7-2) 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) 39 . . . . . . . . . . . . . . . . . . . . . .

7-3. Process/Contactor Switch On CC/CV Models 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − OPERATING AUXILIARY EQUIPMENT 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Generator Power Receptacles (Standard Models) 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Connecting To Optional Three-Phase Generator (CC/CV Standard Models Only) 43 . . . . . . . . . . . . . . . .

8-3. Optional Generator Power Receptacles (Standard Models) 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Generator Power Receptacles (CE Models) 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − MAINTENANCE (DEUTZ F4L2011−POWERED UNITS) 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Routine Maintenance (Deutz F4L2011-Powered Units) 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Maintenance Label 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Servicing Air Cleaner (Deutz F4L2011-Powered Units) 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units) 50 . . . . . . . . . . . . . . . . . . .

9-5. Adjusting Engine Speed (Deutz F4L2011-Powered Units) 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-6. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units) 52 . . . . . . . . . . . . . . . . . . . . . .

9-7. Overload Protection (Deutz F4L2011-Powered Units) 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − MAINTENANCE (DEUTZ F3L912−POWERED UNITS) 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Routine Maintenance (Deutz F3L912-Powered Units) 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Maintenance Label 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Servicing Air Cleaner (Deutz F3L912-Powered Units) 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) 58 . . . . . . . . . . . . . . . . . . . .

10-5. Adjusting Engine Speed (Deutz F3L912-Powered Units) 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-6. Servicing Optional Ether Starting Aid (Deutz F3L912-Powered Units) 59 . . . . . . . . . . . . . . . . . . . . . . . . . .

10-7. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) 60 . . . . . . . . . . . . . . . . . . . . . . .

10-8. Overload Protection (Deutz F3L912-Powered Units) 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − TROUBLESHOOTING 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. Diagnosing Causes Of Engine Fault Shutdowns 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-2. Troubleshooting Tables 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − ELECTRICAL DIAGRAMS 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − RUN-IN PROCEDURE 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-1. Wetstacking 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-2. Run-In Procedure Using Load Bank 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-3. Run-In Procedure Using Resistance Grid 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 14 − GENERATOR POWER GUIDELINES 83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 15 − PARTS LIST 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES
WARRANTY

Declaration of Conformity for

European Community (CE) Products

NOTE

Manufacturer’s Name: Miller Electric Mfg. Co.

Manufacturer’s Address: 1635 W. Spencer Street

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

Appleton, WI 54914 USA

Declares that the product: Big Blue 602D (Deutz F4L1011-Powered Models)

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

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

Noise level of Welding Generators: 2000/14/EC

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

Standards

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

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

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

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

Insulation coordination for equipment within low-voltage systems:

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

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

European Contact: Mr. Danilo Fedolfi, Managing Director

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

Telephone: [phone]

Fax: [phone]

dec_con1 _11/02

Declaration of Conformity for

European Community (CE) Products

NOTE

Manufacturer’s Name: Miller Electric Mfg. Co.

Manufacturer’s Address: 1635 W. Spencer Street

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

Appleton, WI 54914 USA

Declares that the product: Big Blue 602D (Deutz F4L1011-Powered Models)

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

Directives

Noise Level Of Welding Generators: 2000/14/EC

Sound Level Information

Measured Sound Power Level: 98 dB

Guaranteed Sound Power Level: 98 dB

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

Noise conformity assessment procedure followed with notified body:

AV Technology Limited

AVTECH House

Birdhall Lane

Cheadle Heath

Stockport

Cheshire
SK3OXU

Sound power level requirements determined by the 40% duty cycle of 600 A, 30 V

Conforming assessment procedure 1 of Annex VI will be followed.

European Contact: Mr. Danilo Fedolfi, Managing Director

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

Telephone: [phone]

Fax: [phone]

dec_con1 5/98

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom _nd_10/02

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

1-1. Symbol Usage

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

 Marks a special safety message.

 Means “Note”; not safety related.

1-2. Arc Welding Hazards

 The symbols shown below are used throughout this manual to

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

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

pair this unit.

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

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically

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

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

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

 Do not use AC output in damp areas, if movement is confined, or if there is a

danger of falling.

 Use AC output ONLY if required for the welding process.
 If AC output is required, use remote output control if present on unit.
 Additional safety precautions are required when any of the following electri-

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

 Disconnect input power or stop engine before installing or servicing this

equipment. Lockout/tagout input power according to OSHA 29 CFR

1910.147 (see Safety Standards).

 Properly install and ground this equipment according to its Owner’s Manual

and national, state, and local codes.

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

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

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

double-check connections.

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

cord immediately if damaged — bare wiring can kill.

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

arate cable.

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

er electrode from a different machine.

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

Return To Table Of Contents

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

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

once. Maintain unit according to manual.

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

table as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent contact

with any metal object.

 Do not connect more than one electrode or work cable to any single weld

output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop­ping engine.

 Stop engine on inverter and discharge input capacitors according to

instructions in Maintenance Section before touching any parts.

FUMES AND GASES can be hazardous.

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

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

fumes and gases.

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

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

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

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

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

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

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

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

BUILDUP OF GAS can injure or kill.

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

air-supplied respirator.

ARC RAYS can burn eyes and skin.

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

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

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

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

warn others not to watch the arc.

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

and leather) and foot protection.

OM-495 Page 1

WELDING can cause fire or explosion.

HOT PARTS can cause severe burns.

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

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

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

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

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

possible, tightly cover them with approved covers.

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

through small cracks and openings to adjacent areas.

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

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

fire on the hidden side.

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

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

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

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

 Do not use welder to thaw frozen pipes.

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

when not in use.

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

fless trousers, high shoes, and a cap.

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

person before doing any welding.

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

work and have a fire watcher and extinguisher nearby.

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

FLYING METAL can injure eyes.

 Welding, chipping, wire brushing, and grinding cause

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

 Wear approved safety glasses with side shields even

under your welding helmet.

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

a hot engine.

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

bare-handed.

NOISE can damage hearing.

Noise from some processes or equipment can damage
hearing.

 Wear approved ear protection if noise level is high.

MAGNETIC FIELDS can affect pacemakers.

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

near arc welding, gouging, or spot welding opera­tions.

CYLINDERS can explode if damaged.

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

 Protect compressed gas cylinders from excessive heat, mechanical

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

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

cylinder rack to prevent falling or tipping.

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

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

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

connected for use.

 Read and follow instructions on compressed gas cylinders, associated

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

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

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

tive clothing when working on a battery.

 Stop engine before disconnecting or connecting bat-

tery cables or servicing battery.

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

FUEL can cause fire or explosion.

 Stop engine and let it cool off before checking or add-

ing fuel.

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

sparks or open flames.

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

OM-495 Page 2

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

and troubleshooting as necessary.

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

battery cable from battery.

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

and before starting engine.

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

engine from kicking back or starting.

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

nents.

Return To Table Of Contents

MOVING PARTS can cause injury.

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

and securely in place.

STEAM AND 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.

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

FALLING UNIT can cause injury.

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

cylinders, trailer, or any other accessories.

 Use equipment of adequate capacity to lift and

support unit.

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

enough to extend beyond opposite side of unit.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or stop-

ping engine.

 Do not let low voltage and frequency caused by low

engine speed damage electric motors.

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

applicable.

FLYING SPARKS can cause injury.

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

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

 Sparks can cause fires — keep flammables away.

Return To Table Of Contents

OVERUSE can cause OVERHEATING.

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

to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

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

move, or ship PC boards.

TILTING OF TRAILER can cause injury.

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

ing to instructions supplied with trailer.

OM-495 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 i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: [phone], website: www.aws.org).

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

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

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

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

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

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And 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.

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 and www. sparky.org).

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

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

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

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

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

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

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

About Pacemakers:

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

OM-495 Page 4

Return To Table Of Contents

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_fre 8/03

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

2-1. Signification des symboles

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

 Identifie un message de sécurité particulier.

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

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

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

présent manuel pour attirer votre attention et identifier les ris­ques de danger. Lorsque vous voyez un symbole, soyez
vigilant 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 2-6 . Veuillez lire et respecter toutes
ces normes de sécurité.

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

doivent être confiés qu’à des personnes qualifiées.

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

particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

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

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

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

de trous.

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

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

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

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

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

procédé de soudage le demande.

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

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

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

ronnements à risque comme: les endroits humides ou lorsque l’on porte
des vêtements mouillés; sur des structures métalliques au sol, grillages et
échafaudages; dans des positions assises, à genoux et allongées; ou
quand il y a un risque important de contact accidentel avec la pièce ou le
sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence:

1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un
poste à souder manuel (électrode enrobée) DC, 3) un poste à souder ma­nuel AC avec tension à vide réduite. Dans la plupart des cas, un poste
courant continu de type CV est recommandé. Et, ne pas travailler seul!

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

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

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

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

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

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

internes de l’appareil sont également sous tension à ce

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

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

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

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

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

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

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

mal épissés.

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

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

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

une électrode provenant d’une autre machine.

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

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

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

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

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

avec tout objet métallique.

risques de danger reliés

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

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

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

LES FUMÉES ET LES GAZ peuvent
être dangereux.

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

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

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

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

homologué.

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

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

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

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

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

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

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

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

Return To Table Of Contents

OM-495 Page 5

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

 Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

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

rateur d’adduction d’air homologué.

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

Le rayonnement de l’arc du procédé de soudage génère

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

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

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

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

trop élevé.

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

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

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

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

des rayons visibles et invisibles intenses (ultraviolets et

LE SOUDAGE peut provoquer un in­cendie ou une explosion.

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

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

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

chaud.

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

substances inflammables.

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

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

 Des étincelles et des matériaux chauds du soudage peuvent facilement

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

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

clencher un incendie de l’autre côté.

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

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

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

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

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

de ou couper le fil à la pointe de contact.

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

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

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

qu’un allumeur au butane ou des allumettes.

leur éclatement. Des étincelles peuvent être projetées de

 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B

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

DES PARTICULES VOLANTES
peuvent blesser les yeux.

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

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

lantes. Pendant la période de refroidissement des soudures, elles ris­quent de projeter du laitier.

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

des étincelles et des particules métalliques vo-

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Prévoir une période de refroidissement avant d’effec-

tuer des travaux d’entretien.

 Porter des gants et des vêtements de protection pour

travailler sur un moteur chaud.

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

récemment soudées.

LE BRUIT peut affecter l’ouïe.

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

 Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.

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

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

Si des BOUTEILLES sont endomma­gées, elles pourront exploser.

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

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

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

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

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

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

électriques.

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

teille.

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

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

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

ou de branchement de la bouteille.

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

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

2-3. Dangers existant en relation avec le moteur

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

 Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

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

rateur d’adduction d’air homologué.

OM-495 Page 6

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

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

L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gants en

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

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

batterie.

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

batterie.

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

cules de démarrage rapide.

 Observer la polarité correcte (+ et −) sur les batteries.
 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier

lieu.

LE CARBURANT MOTEUR peut pro­voquer un incendie ou une explosion.

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

rant ou de faire le plein.

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

ce d’étincelles ou d’une flamme nue.

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

expansion.

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

rant renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.

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

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

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

nes mobiles.

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

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

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

route accidentelle du moteur.

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

générateur.

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

 Il est préférable de vérifier le liquide de

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

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

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

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

vant :

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

chon du radiateur.

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

d’enlever le bouchon.

LA CHALEUR DU MOTEUR peut pro­voquer un incendie.

DES ORGANES MOBILES peuvent
provoquer des blessures.

 Ne pas approcher les mains des ventilateurs, cour-

roies et autres pièces en mouvement.

 Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de
protection.

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

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

2-4. Dangers liés à l’air comprimé

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

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

ge, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer
des blessures.

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

même.

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

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

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

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

de surfaces inflammables.

 Tenir à distance les produits inflammables de

l’échappement.

LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

 Utiliser uniquement un pare-étincelles approuvé −

voir codes en vigueur.

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

 Ne pas couper ou gouger à proximité de produits

inflammables.

 Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provo­quer des brûlures et blessures.

 Ne pas toucher le compresseur ou d’autres élé-

ments du circuit air comprimé chauds.

 Laisser l’ensemble se refroidir avant de toucher

ou d’effectuer la maintenance.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 Arrêter le moteur et relâcher la pression avant

d’effectuer la maintenance.

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

maintenance

LA CHUTE DE L’APPAREIL peut
blesser.

 Utiliser l’anneau de levage uniquement pour soulever

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

Return To Table Of Contents

 Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

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

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

OM-495 Page 7

LE SURCHAUFFEMENT peut endom­mager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant de dé-

marrer ou d’arrêter le moteur.

 Ne pas laisser tourner le moteur trop lentement sous

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

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

lieu.

LES ÉTINCELLES VOLANTES ris­quent de provoquer des blessures.

 Porter un écran facial pour protéger le visage et les

yeux.

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

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

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

inflammable.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter le facteur de

marche nominal.

 Réduire le courant ou le facteur de marche avant de

poursuivre le soudage.

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

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les
circuits imprimés.

 Établir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques

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

UNE REMORQUE QUI BASCULE peut
entraîner des blessures.

 Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.

 Installer convenablement le poste sur la remorque

comme indiqué dans le manuel s’y rapportant.

LIRE LES INSTRUCTIONS.

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

seur (si applicable) suivant ce manuel et le manuel du
moteur/compresseur (si applicable).

LE RAYONNEMENT HAUTE FRÉ­QUENCE (H.F.) risque de provoquer
des interférences.

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

provoquer des interférences avec les équipements
de radio−navigation et de communication, les
services de sécurité et les ordinateurs.

 Demander seulement à des personnes qualifiées familiarisées avec des

équipements électroniques de faire fonctionner l’installation.

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

fié les interférences résultant de l’installation.

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

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

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

 L’énergie électromagnétique risque de provoquer

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

 Veiller à 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.

2-6. Principales normes de sécurité

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

Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à To­ronto : (416) 747−4044, site Web : www.csa−international.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site
Web : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,
norme NFPA 51B, de la National Fire Protection Association, P.O. Box
9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
770−3000, site Web : www.nfpa.org et www.sparky.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
Web : www.osha.gov).

2-7. Information sur les champs électromagnétiques

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

OM-495 Page 8

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

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

ruban adhésif.

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

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

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

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

Consignes relatives aux stimulateurs cardiaques :

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

SECTION 3 − DEFINITIONS

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

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

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

1 Electric shock from welding

electrode or wiring can kill.

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

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

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

2 Breathing welding fumes can

be hazardous to your health.

2.1 Keep your head out of the
fumes.

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

2.3 Use ventilating fan to remove
fumes.

3 Welding sparks can cause

explosion or fire.

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

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

3.3 Do not weld on drums or any
closed containers.

4 Arc rays can burn eyes and

injure skin.

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

5 Do not remove or paint over

(cover) the label.

6 Engine fuel plus flames or

sparks can cause fire.

6.1 Do not smoke while fueling or if
near fuel.

6.2 Stop engine before fueling.

6.3 Do not fuel a hot engine.

7 Engine exhaust gases can kill.

7.1 Vent exhaust outside.

7.2 Use unit outside.

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3/96

OM-495 Page 9

10

11

1

1

−+

2 3 4 5 6

4

4

1

+ −

+ −

7

2

3

+ −

89 12

3

+ −

S-176 108

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Do not smoke and keep

matches and flames away from
battery.

3 Sparks can cause battery

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

4 Battery acid can burn skin. Do

not spill acid.

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

2

10 Do not connect last negative

cable to dead battery − connect
instead to engine block.

11 Jumper cables − observe

polarity and make connections
in numbered sequence shown.

12 Once dead battery is charged,

disconnect cables in sequence
shown.

3/96

1

2

S-176 106

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Moving parts, such as fans,

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

3/96

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

Starting Instructions:

1 Press and hold Magnetic

Shutdown switch.

2 Turn Engine Control switch to

Start position.

3 Release Engine Control switch

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

4 Continue holding Magnetic

Shutdown switch for 3 seconds
after engine starts.

OM-495 Page 10

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1

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Hot muffler and exhaust pipes

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

2

S-176 230

1

1 Warning! Watch Out! There

3/96

are possible hazards as
shown by the symbols.

2

3

2 Engine fuel plus flames or

sparks can cause fire.

3 Do not smoke while fueling or if

near fuel.

4 Stop engine before fueling.

4

5

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

6

1

2 3 4

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3/96

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Falling equipment can cause

serious injury and damage.

3 Use lifting eye to lift or move

unit only. Use proper
equipment when lifting.

4 Do not use lifting eye to lift and

support unit and trailer or other
heavy devices or accessories.

S-176 104

3/96

OM-495 Page 11

1 Warning! Watch Out! There

are possible hazards as

1

2

5

34

shown by the symbols.

2 Fire hazard from leaking

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

3 Fuel tank is located inside

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

or bolt unit down.

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

1

2

3

2 Electric shock from wiring can

kill.

3 Moving parts, such as fans,

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

OM-495 Page 12

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1

2

3

4

5

0 − 50 h Std.

50 h Std.

+

DIESEL

200A

S-177 571

+

0 − 200A

1 Remove unit from shipping

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

2 Read Owner’s Manual. Read

labels on unit.

3 Use Diesel Fuel only, and fill

fuel tank. Leave room for
expansion.

4 Warning! Watch Out! There

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

5 Check oil level. Add oil if

necessary.

6 During the first 50 hours of

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

7 After the first 50 hours of

operation, change the oil and
oil filter.

API CD-MIL L 2104D,

CD/SE, CD/SF

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

CC Models

3/96

CC/CV Models

Return To Table Of Contents

OM-495 Page 13

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

CC Models

CC/CV Models

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)

OM-495 Page 14

1/2 in (.5 in)

Return To Table Of Contents

3-4. Symbols And Definitions

A

Stop Engine

Starting Aid Battery (Engine)

Check Injectors/

Pump

Positive Negative

Amperes

Fast (Run, Weld/

Power)

Check Valve

Clearance

Volts Panel/Local Remote

V

Air Temperature Or

Engine

Stick (SMAW)

Welding

Engine

Temperature

Constant Current

(CC)

Slow (Idle) Start Engine

Engine Oil

Pressure

Fuel

Certified/Trained

Mechanic

Output

MIG (GMAW)

Welding

Engine Oil

Protective Earth

(Ground)

Welding Arc

Alternating

Current

TIG (GTAW)

3

X

n

Time

h

Three Phase

Electrode

Connection

Duty Cycle

Rated Idle

1

Speed n

Contactor On

U

0

0

Hours

Read Operator’s

Manual

Work Connection

Rated No Load

Voltage (Average)

Rated No Load

Speed

s

G

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

Return To Table Of Contents

OM-495 Page 15

SECTION 4 − SPECIFICATIONS

Option:

Cylinder, 44 HP Diesel

(

)

tip.

A

B

C

°

20°

E

802 161 A

802 311

4-1. Weld, Power, And Engine Specifications

Welding

Mode

CC/DC

CV/DC

(CC/CV

Models

Only)

Weld

Output

Range

55 − 600 A

(CC Models)

20 − 600 A

(CC/CV
Models)

14 − 40 V

Rated Welding

Output

Deutz

F4L2011-Powered

Units:

400 A, 40 Volts DC,

100% Duty Cycle

500 A, 40 volts DC,

60% Duty Cycle

600 A, 30 Volts DC,

40% Duty Cycle

Deutz

F3L912-Powered

Units:

500 A, 40 volts DC,

100% Duty Cycle

600 A, 30 Volts DC,

40% Duty Cycle

Maximum

Open-Circuit

Generator Power

Voltage

95 Standard:

120/240 V AC, 50/60 Hz

Three-Phase Generator

Single-Phase/Three-Phase,

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

120/240 VAC, 60 Hz

56

*In Addition To Standard

4 kVA/kW Generator Power

4 kVA/kW, 34/17 A,

4-2. Dimensions, Weights, And Operating Angles

Dimensions

Height

Width

Depth 65-1/8 in (1654 mm)

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

E 27-1/2 in (699 mm)

F 1 in (25 mm)

G 29-1/2 in (749 mm)

H

* With mounting brackets in center

position. Dimensions vary with
location of mounting brackets.

w/ Deutz

F4L2011

w/ Deutz

F3L912

50 in (1270 mm)

(to top of muffler)

28-1/2 in (724 mm)

(mtg. brackets turned in)

30-3/4 in (781 mm)

(mtg. brackets turned out)

9/16 in (14 mm) Dia.

4 Holes

Weight

No fuel: 1690 lb (767 kg)

w/fuel: 1880 lb (853 kg)

No fuel: 1785 lb (810 kg)

w/fuel: 1975 lb (896 kg)

G

B

C

H

D

Front Panel End

E

Rating

Single-Phase,

Option:*

F

802 161-A

Engine

DEUTZ

Deutz F4L2011

Air/Oil-Cooled, Four

Cylinder, 44 HP Diesel

Engine

or

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

Diesel Engine

 Do not exceed tilt angles or engine could

be damaged or unit could tip.

 Do not move or operate unit where it could

tip.

20°

Fuel

Capacity

25 gal

95 L

°

30

30°

°

802 311

OM-495 Page 16

Return To Table Of Contents

4-3. Volt-Ampere Curves For CC Models

100

80

60

40

DC VOLTS

20

0

0 100 200 300 400 500 600 700 800 900

DC AMPERES

The volt-ampere 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.

Ranges
300−Max

185−425
125−320
85−190
55−90

Notes

203 412

Return To Table Of Contents

OM-495 Page 17

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

A. Stick Mode

100

Ranges

80

300−Max
185−425

125−320

60

85−190
55−90

40

DC VOLTS

20

0

0 100 200 300 400 500 600 700 800 900

DC AMPERES

B. MIG Mode

100

80

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.

60

MAX

40

DC VOLTS

20

MIN

0

0 100 200 300 400 500 600 700 800 900 1000

DC AMPERES

C. TIG Mode

100

Ranges

80

60−310
40−200
30−130

60

20−70

40

DC VOLTS

20

0

0 50 100 150 200 250 300 350 400 450 500

OM-495 Page 18

DC AMPERES

Return To Table Of Contents

203 414 / 203 415 / 203 413

4-5. Fuel Consumption

0

0 50 100 150 200 250 300 350 400 450 500

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

1800 RPM

IDLE

DC WELD AMPERES AT 100% DUTY CYCLE

Notes

193 093

Return To Table Of Contents

OM-495 Page 19

4-6. Duty Cycle And Overheating

A. Deutz F4L-1011-Powered Units

100% Duty Cycle At 400 Amperes

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.

Continuous Welding

B. Deutz F3L912-Powered Units

100% Duty Cycle At 500 Amperes

Continuous Welding

OM-495 Page 20

089 697-D / 202 356

Return To Table Of Contents

4-7. AC Generator Power Curve

300

150

250

125

200

100

150

75

AC VOLTS

100

50

50

25

0

0

0 5 10 15 20 25 30

AC AMPERES IN 240V MODE

0102030405060

AC AMPERES IN 120V MODE

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

Notes

193 018

Return To Table Of Contents

OM-495 Page 21

4-8. Optional Three-Phase Generator Curves

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

280

140

270

135

260

130

250

125

240

120

230

115
110
105
100

95
90

220
210
200
190
180

0

20 40 60 80 100

AC AMPERES

AC VOLTS

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

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

280

260

240

220

200

180

0 10203040506070

AC AMPERES

OM-495 Page 22

197 472 / 197 473

Return To Table Of Contents

Notes

Start Your Professional

Welding Career Now!

400 Trade Square East, Troy, Ohio 45373

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

Return To Table Of Contents

Over 80,000 trained

since 1930!

OM-495 Page 23

SECTION 5 − INSTALLATION

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

Movement

OR OR

Location

OR

OR

 Always securely fasten weld-

ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica­ble codes.

 Always ground generator

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

 If unit does not have GFCI re-

ceptacles, use GFCI-protected
extension cord.

 See Section 5-3 for mounting in-

formation.

Grounding:

1 Equipment Grounding Terminal

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

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

Grounding

GND/PE

Airflow Clearance

1

2

18 in

(460 mm)

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

3

 Bed liners, shipping skids, and some running

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

18 in

(460 mm)

18 in

(460 mm)

OM-495 Page 24

18 in

(460 mm)

18 in

(460 mm)

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

Return To Table Of Contents

5-2. Using Lifting Eye

1 Lifting Eye

1

2

3

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

place. Lower lifting eye when not
needed.

To lock the lifting eye in the upright
position, insert a 3/8-16 x 1-1/2 in
carriage bolt through slot in bracket
and secure with nut (bolt and nut not
supplied).

Tools Needed:

Notes

Ref. 802 169-B / 802 311

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

Return To Table Of Contents

OM-495 Page 25

5-3. Mounting Welding Generator

Supporting The Unit

Inadequate support.

 Do not use flexible mounts.

Using Mounting Brackets

 Do not weld on base. Weld-

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

 Do not mount unit by sup-

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

2

OR

1

1

2

quately support unit and pre­vent damage to base.

Mounting Surface:

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

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

3 1/2 in Bolt And Washer

(Minimum − Not Supplied)

4 3/8-16 x 1 in Screws

(Supplied)

To Bolt Unit In Place:

Remove hardware securing the
four mounting brackets 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:

OM-495 Page 26

9/16 in

Welding Unit In Place

Bolting Unit In Place

3

2

4

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

Return To Table Of Contents

5-4. Installing Exhaust Pipe

 Stop engine and let cool.

 Point exhaust pipe in desired di-

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

Tools Needed:

1/2 in

5-5. Installing Engine Side Baffle (CE Models Only)

Ref. 802 169-E / Ref. 202 705

 Stop engine, and let cool.

1 Engine Side Baffle

(Part No. 212 570)

Loosen four screws securing en­gine side panel.

Position side baffle over side panel.
Tighten screws.

1

Loosen upper and lower
panel mounting screws.

Return To Table Of Contents

Ref. 803 353 / 803 372

OM-495 Page 27

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

5

4

1

3

2

Remove battery from unit.
1 Eye Protection − Safety

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

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

bottom of well (maximum).

 Do not overfill battery cells.

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

6 Battery Charger

 Read and follow all instruc-

tions supplied with battery

charger.

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

 When electrolyte is low, add

only distilled water to cells to

maintain proper level.

5 A For 30 Minutes

30 A For 12 Minutes

OM-495 Page 28

OR

6

Tools Needed:

+

−

Return To Table Of Contents

rubber gloves

glasses

drybatt1 1/98 − 0886

5-7. Connecting The Battery

 Connect Negative (−) Cable Last.

+

Tools Needed:

1/2 in

 Reinstall cover after connecting battery.

−

802 168-E / Ref. 202 705 / 802 313 / S-0756-C

5-8. Installing Optional Ether Cylinder (Deutz F3L912 Engine Only)

 Stop engine.
 Improper handling or expo-

 Do not use Ether Starting Aid

1

Remove rubber access plug from
cover.

1 Ether Cylinder
2 Nozzle
Remove cover and clean cylinder

nozzle.

2

3

4

5

6

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

Install cylinder on fitting. Tighten
clamp.

 After installing cylinder, wait at

Put cap on fitting when cylinder is
removed.

Reinstall plug in cover.

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

while engine is running.

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

Return To Table Of Contents

ether1 7/96 − 153 382-A / Ref. 202 705

OM-495 Page 29

5-9. Engine Prestart Checks

Full

Diesel

Deutz F4L2011 Engine

Full

Full

Diesel

Deutz F3L912 Engine

 Check all engine fluids daily.

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

 This unit has a low oil pressure shut-

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

Follow run-in procedure in engine manual.

OM-495 Page 30

If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 13.

Fuel

 Do not use gasoline. Gasoline will

damage engine.

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

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

Return To Table Of Contents

Full

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).

Ref. 802 313-A / 802 398-A

 To improve cold weather starting:

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

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

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

Use correct grade oil for cold weather
(see Section 9-2 or 10-2).

5-10. Connecting To Weld Output Terminals

1

2

Tools Needed:

3/4 in

 Stop engine.

1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
For Stick and TIG welding Direct Current

Electrode Positive (DCEP), connect elec­trode holder cable to Positive (+) terminal
on left and work cable to Negative (−) ter­minal on right.

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

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

For MIG and FCAW welding Direct Cur­rent Electrode Positive (DCEP) on CC/CV
models, connect wire feeder cable to Pos­itive (+) terminal on left and work cable to
Negative (−) terminal on right. Use Pro­cess/Contactor switch to select type of
weld output (see Section 7-3).

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

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

802 311-A

5-11. 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)

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

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

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

10 − 60%

Duty

Cycle

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

Not Exceeding***

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

60 − 100%

Duty

10 − 100% Duty Cycle

Cycle

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

400 ft

(120 m)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

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

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

* This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger

cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm2 for metric use S-0007-E−
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

Return To Table Of Contents

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

OM-495 Page 31

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

5-12. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models

24 VOLTS AC

OUTPU

distance remote

OUTPUT

1 Remote Amperage Adjust

1

Receptacle RC13
Connect optional remote control to

RC13 (see Section 6-3).

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

5-13. Connecting To Remote 14 Receptacle RC14 On CC/CV Models

New! LDR-14 long

distance remote

(includes 120 V

receptacle)

OR

24 VOLTS AC

REMOTE

T

CONTROL

115 VOLTS AC

Socket* Socket Information

A 24 volts ac. Protected by circuit

breaker CB5.

B Contact closure to A completes

24 volt ac contactor control
circuit.

C Output to remote control:+10

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

D Remote control circuit common.

E DC input command signal: 0 to

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

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

I

CB6.

OM-495 Page 32

*The remaining sockets are not used.

802 311

NEUTRAL G Circuit common for 24 and 115

Return To Table Of Contents

GND

Contact closure to I completes
115 volt ac contactor control

J

circuit.

K Chassis common.

volt ac circuit.

Notes

Return To Table Of Contents

OM-495 Page 33

SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS

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

65

13 18 1914 1210 11

47

9

8

2

OM-495 Page 34

15 16

17

Return To Table Of Contents

3

1

202 705 / 802 311-A

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

Engine Starting Controls

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

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

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

weather starting.
Deutz F4L2011-powered units use a glow

plug starting aid. Push switch up for 60 sec­onds to operate the glow plug before cranking
engine (see starting instructions following).

Deutz F3L912-powered units use an ether
starting aid system. Push switch up and re­lease while cranking engine to release ether
(see starting instructions following).

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

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

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

To Start:

 If engine does not start, let engine come

to a complete stop before attempting re­start.

Above 32 F (0 C): turn Engine Control
switch to Start while pressing Shutdown
switch. Release Engine Control switch when
engine starts. Continue holding Shutdown
switch until engine indicator lights go out.

Below 32 F (0 C) using optional starting
aid switch:

Deutz F4L2011-powered units − Turn Engine
Control switch to Run/Idle position. Push
Starting Aid switch up for 60 seconds. While
still holding Starting Aid switch, press Mag­netic Shutdown switch and turn Engine Con­trol switch to Start. Release Engine Control
switch and Starting Aid switch when engine
starts. Continue holding Shutdown switch un­til engine indicator lights go out.

Deutz F3L912-powered units − Press Mag­netic Shutdown switch and turn Engine Con­trol switch to Start. While cranking engine,
push Starting Aid switch up and release. Re­lease Engine Control switch when engine
starts. Continue holding Shutdown switch un­til engine indicator lights go out.

To Stop: turn Engine Control switch to Off
position.

Engine Indicator Lights

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

ing battery. Engine continues to run.

 Stop engine and fix trouble if Battery

Charging light goes on.

5 Engine Temperature Light
Light goes on and engine stops if engine oil

temperature is above 266 ° F (130° C).

 Stop engine and fix trouble if Engine

Temperature light goes on.

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

is below 22 psi (150 kPa). Light goes on mo­mentarily during start-up but goes out when
engine reaches normal oil pressure.

 Stop engine and fix trouble if Engine

Oil Pressure light stays on after start­up.

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

Engine Gauges

 To read gauges and engine indicator

lights with engine off, turn Engine Control
switch to Run/Idle and press Magnetic
Shutdown switch (see Section 11-1).

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

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

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

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

11 Engine Temperature Gauge (Optional)
Normal temperature is 212 - 239° F (100 -

115 ° C). If equipped with gauge option, engine
stops if temperature exceeds 270° F (132° C).

12 Engine Oil Pressure Gauge (Optional)
Normal pressure is 30 − 60 psi (206 − 414

kPa). If equipped with gauge option, engine
stops if pressure is below 20 psi (138 kPa).

Weld Controls

 Max OCV Control Circuit: This unit has

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

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

13 Ampere Range Switch

 Do not switch under load.

Use switch to select weld amperage range.
For most welding applications, use lowest
amperage range possible to help prevent arc
outages (see Section 6-4).

14 Amperage Adjust Control
Control adjusts amperage within range se-

lected by Ampere Range switch (see Section
6-4). Weld output would be about 223 A DC
with controls set as shown (50% of 125 to 320
A).

 The numbers around the control are for

reference only and do not represent an
actual percentage value.

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

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

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

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

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

16 Amperage Adjust Switch And Remote

Amperage Adjust Receptacle

Connect optional remote control to RC13
(See Section 5-12). Use switch to select front
panel or remote amperage control. For re­mote control, place switch in Remote position
and connect remote control to Remote Am­perage Adjust receptacle RC13 (see Sec­tions 5-12 and 6-3).

17 Polarity Switch (Optional)

 Do not switch under load.

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

Weld Meters

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

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

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

unit.

Return To Table Of Contents

OM-495 Page 35

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

1

1 Remote Amperage Adjust

Receptacle RC13
Connect optional remote control to

RC13 (see Section 5-12).

Example: Combination Remote Amperage Control (Stick)

6-4. Weld Control/Arc Condition Information Label

In Example:

Range = 125 to 320 A DC

Percentage Of Range = 50%

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

Max (223 A DC)

Min (87 A DC)

Adjust Optional Remote ControlSet Switches Set Range Set Control

0774 / Ref. 154 862-A / Ref. 181 711-A / 802 311-A

 Set weld controls as shown to

achieve softer or stiffer arc condi­tions for different applications.

OM-495 Page 36

212 944-A

Return To Table Of Contents

Notes

Return To Table Of Contents

OM-495 Page 37

SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS

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

65

14 18 1915 1210 11

47

9

8

2

OM-495 Page 38

13 16

17

Return To Table Of Contents

3

1

202 706 / 802 311-D

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

Engine Starting Controls

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

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

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

weather starting.
Deutz F4L2011-powered units use a glow

plug starting aid. Push switch up for 60 sec­onds to operate the glow plug before cranking
engine (see starting instructions following).

Deutz F3L912-powered units use an ether
starting aid system. Push switch up and re­lease while cranking engine to release ether
(see starting instructions following).

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

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

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

To Start:

 If engine does not start, let engine come

to a complete stop before attempting re­start.

Above 32 F (0 C): turn Engine Control
switch to Start while pressing Shutdown
switch. Release Engine Control switch when
engine starts. Continue holding Shutdown
switch until engine indicator lights go out.

Below 32 F (0 C) using optional starting
aid switch:

Deutz F4L2011-powered units − Turn Engine
Control switch to Run/Idle position. Push
Starting Aid switch up for 60 seconds. While
still holding Starting Aid switch, press Mag­netic Shutdown switch and turn Engine Con­trol switch to Start. Release Engine Control
switch and Starting Aid switch when engine
starts. Continue holding Shutdown switch un­til engine indicator lights go out.

Deutz F3L912-powered units − Press Mag­netic Shutdown switch and turn Engine Con­trol switch to Start. While cranking engine,
push Starting Aid switch up and release. Re­lease Engine Control switch when engine
starts. Continue holding Shutdown switch un­til engine indicator lights go out.

To Stop: turn Engine Control switch to Off
position.

Engine Indicator Lights

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

ing battery. Engine continues to run.

 Stop engine and fix trouble if Battery

Charging light goes on.

5 Engine Temperature Light
Light goes on and engine stops if engine oil

temperature is above 266 ° F (130° C).

 Stop engine and fix trouble if Engine

Temperature light goes on.

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

is below 22 psi (150 kPa). Light goes on mo­mentarily during start-up but goes out when
engine reaches normal oil pressure.

 Stop engine and fix trouble if Engine

Oil Pressure light stays on after start­up.

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

Engine Gauges

 To read gauges and engine indicator

lights with engine off, turn Engine Control
switch to Run/Idle and press Magnetic
Shutdown switch (see Section 11-1).

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

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

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

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

11 Engine Temperature Gauge (Optional)
Normal temperature is 212 - 239° F (100 -

115 ° C). If equipped with gauge option, engine
stops if temperature exceeds 270° F (132° C).

12 Engine Oil Pressure Gauge (Optional)
Normal pressure is 30 − 60 psi (206 − 414

kPa). If equipped with gauge option, engine
stops if pressure is below 20 psi (138 kPa).

Weld Controls

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

switch information.

14 Ampere Range Switch

 Do not switch under load.

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

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

Use the highest range for MIG welding and for
cutting and gouging (CAC-A).

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

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

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

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

 The numbers around the control are for

reference only and do not represent an
actual percentage value.

16 Voltage/Amperage Adjust Switch And

Remote 14 Receptacle

Use switch to select front panel or remote
voltage/amperage control. For remote con­trol, place switch in Remote position and con­nect remote control to Remote 14 receptacle
RC14 (see Sections 5-13 and 7-4).

17 Polarity Switch (Optional)

 Do not switch under load.

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

Weld Meters

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

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

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

unit.

Return To Table Of Contents

OM-495 Page 39

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

1 Process/Contactor Switch

 Weld output terminals are ener-

gized when Process/Contactor
switch is in an Electrode Hot posi-

1

tion and the engine is running.

 DC voltage is still present at the

weld terminals when Process/
Contactor switch is in the Remote

− Stick position and the engine is
running.

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

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

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

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

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

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

 Place switch in Electrode Hot - Stick

position when using optional three­phase generator (see Section 7-4).

 The engine auto idle option does not

work in the Remote-TIG mode.

Process/Contactor Switch Settings

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

Remote − TIG

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

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

Electrode Hot − MIG MIG (GMAW) Electrode Hot Active

Electrode Hot − Stick

Electrode Hot − Scratch

Start TIG

GTAW With HF Unit, Pulsing

Device, Or Remote Control

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting

And Gouging

Scratch Start TIG (GTAW) Electrode Hot Active

At Remote 14 Receptacle Not Active

Electrode Hot Active

202 706

OM-495 Page 40

Return To Table Of Contents

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

1 Remote 14 Receptacle RC14
Connect optional remote control to

RC14 (see Section 5-13).

1

Example: Combination Remote Amperage Control (Stick)

Set V/A

Adjust Switch

Example: Combination Remote Amperage Control (TIG)

Set Remote

Process

Set Range Control Not

Used In Remote

Stick Mode

Process = Stick (Using Remote On/Off)

In Example:

Range = 125 to 320 A DC

Min = 125 A DC

Max = 320 A DC

Max (320 A DC)

Min (125 A DC)

Adjust Optional Remote Control

In Example:

Process = TIG (Using Remote On/Off)

Range = 40 to 200 A DC

Percentage Of Range = 50%

Min = 40 A DC

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

Set V/A

Adjust Switch

Set Remote

Process

Set Range Set Control

Return To Table Of Contents

Max (120 A DC)

Min (40 A DC)

Adjust Optional Remote Control

0774 / Ref. 192 895-A / 802 311-A

OM-495 Page 41

SECTION 8 − OPERATING AUXILIARY EQUIPMENT

8-1. Generator Power Receptacles (Standard Models)

1

3

4

1 120 V 20 A AC GFCI

Receptacle GFCI1

2 240 V 30 A AC Twistlock

Receptacle RC1

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

2

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

 At least once a month, run en-

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

3 Circuit Breaker CB1
4 Circuit Breaker CB2
CB1 protects RC1 and the genera-

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

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

 If a circuit breaker continues t o

open, contact Factory Autho­rized Service Agent.

 Generator power is not af-

fected by weld output.

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

EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:

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

4.0 kVA/kW

OM-495 Page 42

191 624

Return To Table Of Contents

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

 Place Process/Contactor switch

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

Single-Phase Power Connection

Three-Phase Power Connection

Remove plug
before inserting
leads. Reinstall
bushing.

5

6

7

9

8

12

 Close panel opening

if no connections are
made to generator.

Rear Of Panel

91 92 93

240V

120V

120V

240V

240V

1-Phase

240V

3-Phase

AC

Output

Volts

Amps

KVA/KW

Engine Speed 1850 RPM

Lead 42 connects to GROUND stud on
front of unit.

Jumper 42 is connected to 90 at factory.

Single
Phase

1

120/240

50
12

Three

Phase

3

240

48
20

60 HzFrequency

4

3

2

12

10

11

 Close panel

opening if no
connections
are made to
generator.

Tools Needed:

93

91

90

92

tor (see Section 7-3).

Single-Phase Generator Power

1 120/240 V 50 A Receptacle

RC5

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

2 Circuit Breaker CB7
Circuit breaker CB7 protects single-

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

Three-Phase Generator Power

 Stop engine.
 Power and weld outputs are

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

 Have qualified person install ac-

cording to circuit diagram and
Generator Power Guidelines
(see Section 14).

Remove generator power panel
mounting screws. Tilt panel forward.

3 Lead 93
4 Lead 92
5 Lead 91
6 Lead 42 (Circuit Grounding

Lead)
7 Lead 90 (Neutral)
8 Isolated Neutral Terminal
9 Jumper Lead 42
10 Grounding Terminal
Jumper 42 is connected to lead 90 at

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

Lead 42 connects to front panel
Ground stud.

11 User-Supplied Leads
12 Circuit Breaker CB7 User

Terminals
Connect user-supplied leads to ter-

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

 Circuit breaker CB7 protects

single-phase receptacle RC5

and the load wires from overload.

If CB7 opens, all three-phase

generator output stops and the

receptacle does not work.

Reinstall generator power panel.

Return To Table Of Contents

Ref. 197 399 / 802 332-B

OM-495 Page 43

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

European Receptacle

5

6

Australian Receptacle

5

6

South African Receptacle

5

6

1

2

31

41

1 120 V 20 A AC GFCI

Receptacle GFCI1

2 240 V 16 A AC European

Receptacle RC1

3 240 V 15 A AC Australian

Receptacle RC1

4 240 V 15 A AC South African

Receptacle RC1

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

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

 At least once a month, run en-

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

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

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

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

 If a circuit breaker continues t o

open, contact Factory Autho­rized Service Agent.

 Generator power is not af-

fected by weld output.

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

EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:

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

4.0 kVA/kW

OM-495 Page 44

191 624

Return To Table Of Contents

8-4. Generator Power Receptacles (CE Models)

14 2 35

 Generator power is not affected by weld

output.

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

power at weld/power speed.
4 Circuit Breaker CB1
5 Circuit Breakers CB2 And CB3
CB1 protects RC1 and the generator wind-

ing from overload. If CB1 opens, RC1 and
RC2 do not work. Place switch in On position
to reset breaker.

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

 If a circuit breaker continues to open,

contact Factory Authorized Service
Agent.

Ref. 204 258

Maximum output is 4 kVA/kW from RC1 and

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

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

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

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

Return To Table Of Contents

OM-495 Page 45

SECTION 9 − MAINTENANCE (DEUTZ F4L2011−POWERED UNITS)

Note

Note

The oil/filter maintenance intervals are different for the Deutz F4L2011 and F3L912 engines
(see maintenance schedules following).

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

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

 Stop engine before maintaining.

Recycle

engine

fluids.

 See Engine Manual and Maintenance Label for

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

* To be done by Factory Authorized Service Agent.

Every 8 h

Wipe Up

Spills.

Check Fluid
Levels. See
Section 5-9.

Every 50 h

Clean Air Filter.

See Section 9-3.

FUEL

WATER

Drain Water

From Fuel

System. See

Section 9-6.

Clean And

Tighten Weld

Terminals.

Replace

Unreadable

Labels.

Clean

Cooling

System.

Check air cleaner
hoses for cracks
and loose clamps.

1/2 in.

(13 mm)

Every 100 h

Every 250 h

Check

Belt

Tension.

Every 500 h

Clean And

Tighten
Battery

Connections.

Check And

Clean Spark

Arrestor. See

Section 9-4.

Repair Or

Replace
Cracked

Cables.

OM-495 Page 46

Return To Table Of Contents

SLUDGE

FUEL

Change Oil. See

Section 9-6.

Change Fuel

Filters. See

Section 9-6.

Drain Sludge

From Fuel

Tank. See

Section 9-6.

OR

Every 1000 h

Change Oil Filter.

See Section 9-6.

Service more often

in dirty conditions.

Service Welding

Generator Brushes

And Slip Rings.
Service More Often
In Dirty Conditions.*

Check

Valve

Clearance.*

Blow Out Or

Vacuum Inside.

During Heavy

Service,

Clean Monthly.

Every 3000 h

Notes

Clean/Set
Injectors.*

Return To Table Of Contents

OM-495 Page 47

9-2. Maintenance Label

OM-495 Page 48

Return To Table Of Contents

9-3. Servicing Air Cleaner (Deutz F4L2011-Powered Units)

2

Optional

Keep nozzle

2 in (51 mm)

from element.

Blow Inspect

41 3

 Stop engine.
 Do not run engine without air

cleaner or with dirty element. En­gine damage caused by using a
damaged element is not covered
by the warranty.

 The air cleaner primary element can

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

5

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

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

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

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

To clean air filter:

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

 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).

Return To Table Of Contents

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

OM-495 Page 49

9-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units)

 Stop engine and let cool.

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

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

blow out cleanout hole. If nothing
blows out of hole, briefly cover end

3

2

1

of exhaust pipe with fireproof
material.

 Stop engine and let cool.

Reinstall cleanout plug.

Tools Needed:

3/8 in

Notes

802 170-A / Ref. 202 705 / Ref. 802 311-A / Ref. 802 160-B

OM-495 Page 50

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9-5. Adjusting Engine Speed (Deutz F4L2011-Powered Units)

1850 rpm Max.
(61.6 Hz)

1250 rpm
(41.5 Hz)

Standard Models

2

1

Models With Automatic Idle (Optional)

 Stop engine and let cool.

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

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

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

Contactor switch to Stick − Elec­trode Hot position.

Standard Models:

1 Engine Speed Adjustment

Screw
2 Locking Nut
Loosen nut. Turn screw until engine

runs at weld/power speed. Tighten
nut.

 Do not set engine speed higher

than specified.

Models With Automatic Idle
(Optional)

3 Throttle Rod
4 Locknut
Loosen locknuts. Place engine

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

idle speed. Tighten locknuts.
5 Engine Speed Adjustment

Screw
6 Locknut
Place engine control switch in Run

position.
Loosen locknut. Turn screw until

engine runs at weld/power speed.
Tighten locknut.

 Do not set engine speed higher

than specified.

 Stop engine.

Close door.

Tools Needed:

3/8, 7/16 in

4 3

5

6

Return To Table Of Contents

802 313-A

OM-495 Page 51

9-6. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units)

Tools Needed:

3

6

4

7/16, 11/16 in

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

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

1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary Fuel Filter (Fuel/Water Sepa-

rator)
5 Petcock
6 Secondary Fuel Filter
7 Fuel Tank Sludge Drain Valve

To change oil and filter:

Route oil drain hose and valve through hole
in base. See engine manual and engine

OM-495 Page 52

1

7

maintenance label for oil/filter change in­formation.

To drain water from fuel system:

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

To replace primary fuel filter:

Turn filter counterclockwise. Remove filter.
Apply thin coat of fuel to gasket on new filter.

Fill filter with fuel. Install filter and turn clock­wise. Bleed air from fuel system according
to engine manual.

Inspect fuel line, and replace if cracked or
worn.

To replace secondary fuel filter:

Return To Table Of Contents

5

2

Ref. 800 159-E / Ref. 802 170 / 802 313-A

See engine manual.
Close doors.

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

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

 Properly lift unit and secure in a level

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

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

9-7. Overload Protection (Deutz F4L2011-Powered Units)

21

9

8

7

4

5

 Stop engine.

 When a circuit breaker or fuse opens,

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

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

ing from overload. If F1 opens, weld and
generator power is low or stops entirely.
If F2 opens, weld output is low or stops
entirely. 4 kVA/kW generator power is still
available.

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

(CC/CV Models Only)

5 Circuit Breaker CB6

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

(Optional − Not Shown)
CB4 protects the welding arc drive (dig)

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

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

CB6 protects the 115 volt ac output to re­mote receptacle RC14 (CC/CV models
only). If CB6 opens, 115 volt output to
RC14 stops.

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

CB11 protects the engine wiring harness.
On CC models, if CB11 opens the max
OCV circuit does not work and open cir­cuit voltage is variable at all times (see
max OCV note under Weld Controls in
Section 6-2). If CB11 opens on CC/CV
models, weld output stops (generator
power is still available).

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

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

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

Press button to reset breaker.

802 170-D / Ref. 802 311

Return To Table Of Contents

OM-495 Page 53

SECTION 10 − MAINTENANCE (DEUTZ F3L912−POWERED UNITS)

Note

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

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

 Stop engine before maintaining.

Recycle

engine

fluids.

 See Engine Manual and Maintenance Label for

* To be done by Factory Authorized Service Agent.

Every 8 h

Wipe Up

Spills.

Check Fluid
Levels. See
Section 5-9.

Every 50 h

Clean Air Filter.

See Section

10-3.

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

FUEL

WATER

Drain Water

From Fuel

System. See

Section 10-7.

Clean And

Tighten Weld

Terminals.

Clean

Cooling

System.

Check air cleaner
hoses for cracks
and loose clamps.

Replace

Unreadable

Labels.

Every 100 h

Every 250 h

1/2 in.

(13 mm)

Check And

Clean Spark
Arrestor. See
Section 10-4.

Clean And

Tighten
Battery

Connections.

Check

Belt

Tension.

OM-495 Page 54

Return To Table Of Contents

Change Oil. See

Section 10-7.

Check

Valve

Clearance.*

Change Fuel

Filters. See

Section 10-7.

Every 500 h

Change Oil Filter.

See Section 10-7.

Service more often

in dirty conditions.

Repair Or

Replace

Cracked

Cables.

Every 1000 h

Service Welding

Generator Brushes

And Slip Rings.

Service More Often

In Dirty Conditions.*

SLUDGE

Notes

FUEL

Drain Sludge

From Fuel

Tank. See

Section

10-7.

OR

Every 3000 h

Clean/Set
Injectors.*

Blow Out Or

Vacuum Inside.

During Heavy

Service,

Clean Monthly.

Return To Table Of Contents

OM-495 Page 55

10-2. Maintenance Label

OM-495 Page 56

Return To Table Of Contents

10-3. Servicing Air Cleaner (Deutz F3L912-Powered Units)

2

Optional

Keep nozzle

2 in (51 mm)

from element.

Blow Inspect

 Stop engine.
 Do not run engine without air

41 3

cleaner or with dirty element. En­gine damage caused by using a
damaged element is not covered
by the warranty.

 The air cleaner primary element can

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

5

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

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

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

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

To clean air filter:

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

 Do not clean housing with air

hose.

Clean primary element with compressed
air only.

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

Reinstall primary element and cap (dust
ejector down).

Return To Table Of Contents

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

OM-495 Page 57

10-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units)

 Stop engine and let cool.

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

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

blow out cleanout hole. If nothing
blows out of hole, briefly cover end

3

2

1

of exhaust pipe with fireproof
material.

 Stop engine and let cool.

Reinstall cleanout plug.

Tools Needed:

3/8 in

Notes

802 170-A / Ref. 202 705 / Ref. 802 311-A / Ref. 802 160-B

OM-495 Page 58

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10-5. Adjusting Engine Speed (Deutz F3L912-Powered Units)

Engine Speed

(No Load)

Weld/Power

2

1

RPM

1850

 Stop engine.

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

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

weld/power speed. Tighten locknut.

 Do not set engine speed higher

than specified.

 Stop engine.

Close side door.

10-6. Servicing Optional Ether Starting Aid (Deutz F3L912-Powered Units)

 Stop engine.
 Improper handling or expo-

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

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

Remove cylinder from valve.

1

3

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

valve fitting is clean.
Replace cylinder according to

Section 5-8.

Tools Needed:

9/16, 7/8 in

802 398 / 134 730-C

(935 g) (425 g)

Full Empty

15 oz33 oz

Return To Table Of Contents

2

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

OM-495 Page 59

10-7. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units)

Tools Needed:

6

3

4

7/16, 11/16 in

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

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

1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary Fuel Filter (Fuel/Water Sepa-

rator)
5 Petcock
6 Secondary Fuel Filter
7 Fuel Tank Sludge Drain Valve

To change oil and filter:

Route oil drain hose and valve through hole
in base. See engine manual and engine

OM-495 Page 60

1

7

maintenance label for oil/filter change in­formation.

To drain water from fuel system:

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

To replace primary fuel filter:

Turn filter counterclockwise. Remove filter.

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

Inspect fuel line, and replace if cracked or
worn.

To replace secondary fuel filter:

Return To Table Of Contents

5

2

Ref. 800 159-E / Ref. 802 170 / 802 398

See engine manual.
Close doors.

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

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

 Properly lift unit and secure in a level

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

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

10-8. Overload Protection (Deutz F3L912-Powered Units)

21

9

8

7

4

5

 Stop engine.

 When a circuit breaker or fuse

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

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

ing from overload. If F1 opens, weld and
generator power is low or stops entirely.
If F2 opens, weld output is low or stops
entirely. 4 kVA/kW generator power is still
available.

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

(CC/CV Models Only)

5 Circuit Breaker CB6

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

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

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

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

CB6 protects the 115 volt ac output to re­mote receptacle RC14 (CC/CV models
only). If CB6 opens, 115 volt output to
RC14 stops.

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

CB11 protects the engine wiring harness.
On CC models, if CB11 opens the max
OCV circuit does not work and open cir­cuit voltage is variable at all times (see
max OCV note under Weld Controls in
Section 6-2). If CB11 opens on CC/CV
models, weld output stops (generator
power is still available).

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

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

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

Press button to reset breaker.

Ref. 802 313-A

Return To Table Of Contents

OM-495 Page 61

SECTION 11 − TROUBLESHOOTING

11-1. Diagnosing Causes Of Engine Fault Shutdowns

Pre-Start Diagnostic Checks

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

 Correct the cause of the shut-

down before operating the
welding generator.

 This unit does not have a bat-

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

Turn Engine Control Switch To Run/Idle

Position While Pressing Magnetic

Shutdown Switch.

Diagnostic Checks While Running

Normal Condition:

Oil Pressure Light On;

Battery Charging And Temperature Lights Off.

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

If Battery Charging Light Is On, Have Factory Authorized Service

Agent Check Alternator.

If Temperature Light Is On, Correct Cause Of Overheating

(See Engine Manual).

If Engine Is Okay, See Factory Authorized Service Agent.
If Fault Continues, See Factory Authorized Service Agent.

20s

Start Engine (With No Load Applied).

OM-495 Page 62

Continue Pressing Shutdown Switch

Until Engine Lights Go Off.

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Engine Lights Go Off As Engine Reaches

Normal Condition:

Normal Operating Condition.

Lights That Stay On After 20 Sec. Indicate Fault

Condition.

Stop Engine And Correct Fault (See Above) If Fault

Continues, See Factory Authorized Service Agent.

Ref. 202 705

11-2. Troubleshooting Tables

A. Welding − CC Models

Trouble Remedy

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

No weld output or generator power out­put at ac receptacles.

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

High weld output. Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).

Low weld output. Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).

Check position of Ampere Range switch.

Check position of optional polarity switch.

Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
control to Remote Amperage Adjust receptacle RC13 (see Sections 5-12 and 6-1).

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-12).

Check fuse F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent check inte­grated rectifier SR2 and the rotor.

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

Disconnect equipment from generator power receptacles during start-up.

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (see Section 9-7
or 10-8).

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

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Have Factory Authorized Service Agent check brushes and slip rings.

Have Factory Authorized Service Agent check OCV control circuit.

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

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

Low open-circuit voltage. Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).

Maximum weld output only in each
ampere range (with Stick/TIG Selection
switch in Stick position).

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

Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-7
or 10-8). Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and
SR5.

Have Factory Authorized Service Agent check control relay CR7.

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-12).

Repair or replace remote control device.

Reset circuit breaker CB11 (see Section 9-7). Have Factory Authorized Service Agent check control relay
CR7.

Have Factory Authorized Service Agent check OCV control circuit.

Have Factory Authorized Service Agent check control relay CR7.

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OM-495 Page 63

B. Welding − CC/CV Models

Trouble Remedy

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

No weld output or generator power out­put at ac receptacles.

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

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

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

Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and
connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-13 and 7-1).

Check position of Ampere Range switch.

Check position of optional polarity switch.

Reset circuit breaker CB11 (see Section 9-7 or 10-8).

Reset circuit breaker CB5 (see Section 9-7 or 10-8). Check for faulty remote device connected to
RC14.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-13).

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

Check fuse F2, and replace if open (see Section 9-7 or 10-8). Have Factory Authorized Service Agent
check brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor.

Disconnect equipment from generator power receptacles during start-up.

Check fuses F1 and F2, and replace if open (see Section 9-7 or 10-8). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

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

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).

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

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

Low weld output. Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).

Check fuses F1 and F2, and replace if open (see Section 9-7 or 10-8). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

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

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

No remote fine amperage or voltage
control.

Constant speed wire feeder does not
work.

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

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

Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-7
or 10-8). Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and
SR5.

Place Voltage/Amperage Adjust switch in Remote position.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-13).

Repair or replace remote control device.

Reset circuit breaker CB5 or CB6 (see Section 9-7 or 10-8).

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-13).

Repair or replace wire feeder.

Repair or replace remote control device.

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

OM-495 Page 64

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C. Standard Generator Power

Trouble Remedy

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

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

High output at generator power ac re­ceptacles.

Low output at generator power ac recep­tacles.

Reset receptacle circuit breakers.

Check fuses F1 and F2, and replace if open (see Section 9-7 or 10-8). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, and the rotor.

Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (CC models) or field
current regulator board PC1 (CC/CV models) (see Section 9-7 or 10-8).

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

Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).

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

Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).

Check fuse F1, and replace if open (see Section 9-7 or 10-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, resistor R3, and capacitor C9.

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

Trouble Remedy

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

Place Process/Contactor switch in Electrode Hot - Stick position (see Section 7-3).

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

Reset circuit breaker CB5 (see Section 9-7 or 10-8).

Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).

Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
PC1.

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

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

Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).

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

Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
PC1.

E. Engine

Trouble Remedy

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

Check battery connections and tighten if necessary.

Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-7
or 10-8). Have Factory Authorized Service Agent check engine wiring harness and components.

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check Engine Control switch S1.

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OM-495 Page 65

Trouble Remedy

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

Check fuel level.

Reset circuit breaker CB13 (see Section 9-7 or 10-8). Have Factory Authorized Service Agent check en­gine wiring harness and components.

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

On Deutz F3L912-powered units, allow circuit breaker CB14 to reset. Have Factory Authorized Service
Agent check fuel solenoid FS1 (see Section 10-8).

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

Air in fuel system. See engine manual.

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

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

Engine suddenly stops. Check fuel level.

Engine slowly stopped and cannot be
restarted.

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

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

Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Sections 5-9 and 11-1).

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

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

Use correct grade oil for cold weather (see Section 9-2 or 10-2).

Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Sections 5-9 and 11-1).

See engine manual.

Check fuel level.

Check engine air and fuel filters (see Sections 9-3 and 9-6, or Sections 10-3 and 10-7).

See engine manual.

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

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

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

OM-495 Page 66

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

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months).

Have Factory Authorized Service Agent check idle module PC7.

Check for obstructed throttle solenoid.

CC models: place Stick/TIG Selection switch in Stick position.
CC/CV models: place Process/Contactor switch in any position but Remote-TIG.

Check for obstructed throttle solenoid.

Allow circuit breaker CB14 to reset. Have Factory Authorized Service Agent check throttle solenoid TS1
and linkage (see Section 9-7).

Have Factory Authorized Service Agent check idle module PC7, control relays CR3 and CR6, and current
transformer CT1.

Dry engine (see Section 13).

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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)

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1/2 in (.5 in)

OM-495 Page 67

SECTION 12 − ELECTRICAL DIAGRAMS

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

OM-495 Page 68

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215 302-A

OM-495 Page 69

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

OM-495 Page 70

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216 530-A

Return To Table Of Contents

OM-495 Page 71

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

OM-495 Page 72

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215 303-A

OM-495 Page 73

OM-495 Page 74

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

Deutz F4L2011-Powered Units)

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216 531-A

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OM-495 Page 75

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

OM-495 Page 76

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215 298-A

OM-495 Page 77

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

OM-495 Page 78

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215 299-A

OM-495 Page 79

13-1. Wetstacking

1

SECTION 13 − 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.

OM-495 Page 80

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13-2. Run-In Procedure Using Load Bank

4

2

3

 Stop engine.
 Do not touch hot exhaust

pipe, engine parts, or load
bank/grid.

 Keep exhaust and pipe away

from flammables.

 Do not perform run-in

procedure at less than 20

1

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

1 Load Bank
Turn all load bank switches Off. If

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

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

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

3 Weld Cables
Connect load bank to generator

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

Start engine and run for several
minutes.

Set load bank switches and then
adjust generator A/V control so load
equals rated voltage and current of
generator (see nameplate, rating
label, or the specifications section
in this manual).

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

 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.

Return To Table Of Contents

S-0683

OM-495 Page 81

13-3. Run-In Procedure Using Resistance Grid

6

2

3

4

+

5

 Stop engine.
 Do not touch hot exhaust

pipe, engine parts, or load
bank/grid.

 Keep exhaust and pipe away

from flammables.

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

3 Weld Cables
Connect grid to generator weld

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

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

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

minutes.
Set grid switches and then adjust

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

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

 Check oil level frequently dur-

ing run-in; add oil if needed.

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

 Stop engine and let cool.

6 Engine Exhaust Pipe
Repeat procedure if wetstacking is

present.

OM-495 Page 82

S-0684

Return To Table Of Contents

SECTION 14 − 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.

14-1. 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

14-2. 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.

Return To Table Of Contents

S-0854

OM-495 Page 83

14-3. 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.

14-4. 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 14-8).

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

OM-495 Page 84

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

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

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

S-0623

Return To Table Of Contents

14-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

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

Capacitor Start-Induction Run 1/3 HP 2020 720

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

1 HP 6100 1600

1-1/2 HP 8200 2200

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

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

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

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

14-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts

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

1-1/2 HP 8200 2200

2 HP 10550 2850
3 HP 15900 3900

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

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

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

Return To Table Of Contents

OM-495 Page 85

14-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

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

Circular Saw 6-1/2 in 500 500

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

Table Saw 9 in 4500 1500

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

8 in 3900 1400

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

1 HP 6000 1500

1-1/2 HP 8200 2200

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

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

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

Metal Halide 313 250

Mercury 1000

Sodium 1400

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

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

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

2-1/2 HP 1300 1300

OM-495 Page 86

Return To Table Of Contents

14-8. Power Required To Start Motor

4
1

VOLTS AMPS

3

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GH J 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

14-9. How Much Power Can Generator Supply?

1

2

1 Limit Load To 90% Of

Generator Output

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

2 5 Second Rule
If motor does not start within 5

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

Return To Table Of Contents

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

OM-495 Page 87

14-10. 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 14-4).

OM-495 Page 88

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

Return To Table Of Contents

14-11. Selecting Extension Cord (Use Shortest Cord Possible)

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

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

Current

(Amperes)

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

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

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

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

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

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

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

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

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

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

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

Load (Watts) 4 6 8 10 12 14

Current

(Amperes)

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

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

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

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

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

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

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

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

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

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

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

*Conductor size is based on maximum 2% voltage drop

Load (Watts) 4 6 8 10 12 14

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

Return To Table Of Contents

OM-495 Page 89

 Hardware is common and not

available unless listed.

 A Deutz F4L2011 engine-pow-

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

SECTION 15 − PARTS LIST

15

127

107

1

2

108(CV)

109(CV)

3

103

14

13

12

4

5 6

8

7

102 (Fig. 14-7)

11

9

10

12

101

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

97 (CC ONLY)

98

16

17

92

18

19

94

20

21

22

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

OM-495 Page 90

105

99 (CC ONLY)

104

CC CC Models Only
CV CC/CV Models Only

95

93

96

Figure 15-1. Main Assembly

Return To Table Of Contents

 A Deutz F4L2011 en-

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

121

120

Deutz F3L912 Engine

29

32

119

110

112

122

126

54

124

23

24

25

26

27

28

123

29

125

32

115

34 (Fig. 15-6)

30

42

114

111

118

113

16

17

117

67

69

70

71

72

65

62

64

43

63

61

60

59

58

116

44

45

46

55

49

56

47

48

50

51

52

83

34 (Fig. 15-6)

86

84

85

35

31

36

87

37

88

91

89

38

39

33

90

40

41

68

67

66

69

70

71

72

63

65

62

64

61

59

81

55

56

57

60

58

73

82

54

74

80

75

53

54

76

77

78

79

92

Return To Table Of Contents

802 331-F

OM-495 Page 91

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 15-1. Main Assembly

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

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

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

2 176 106 LABEL, warning moving parts (Wordless Label) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

♦212 570 Baffle, engine side (CE Rated) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

8 SR4, SR5 035 704 RECTIFIER, integ bridge 40. amp 800v 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

26 192 041 LABEL, use diesel fuel only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 176 103 LABEL, use diesel fuel only (Wordless Label) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 108 487 LABEL, warning falling equipment 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 176 104 LABEL, warning falling equipment (Wordless Label) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 176 230 LABEL, warning hot exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

29 201 592 PIPE, exhaust (CE Rated) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 201 851 COVER, radiator access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 191 354 SUPPORT, cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 202 633 SUPPORT, cover e-coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 010 875 CLAMP, muffler 2.000 dia u pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 200 730 MANIFOLD, exhaust muffler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 Figure 15-6 GENERATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 013 367 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 176 106 LABEL, warning moving parts (Deutz F4L2011) (Wordless Label) 2. . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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Figure 15-1. Main Assembly (Continued)

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

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

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

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

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

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

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

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

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

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

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

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

44 190 206 CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 108 081 TERMINAL PROTECTOR, battery post mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 190 207 CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 203 430 BRACKET, battery holddown 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 190 897 BATTERY, stor 12V 650crk 110rsv gp 24 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 201 006 BOLT, j stl .312−18 x 8.500 pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 +201 183 COVER, battery access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 202 639 COVER, battery access ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 168 385 LABEL, warning battery explosion can blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 176 108 LABEL, warning battery explosion can blind (Wordless Label) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

52 147 923 LABEL, warning moving parts can cause serious injury 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 176 106 LABEL, warning moving parts (Wordless Label) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 +215 252 GUARD, belt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 147 923 LABEL, warning moving parts can cause serious injury 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 199 849 SCREW, 625-11 x 4.00hexhd pln gr 5 pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 071 731 WASHER, flat .656 ID x 2.250 OD x .187T stl pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 191 812 BRACKET, mtg engine RH (Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 071 890 RETAINER, mount eng/gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 071 730 TUBING, stl .875 OD x 12ga wall x 2.500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 083 476 MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 135 205 NUT, 625-11 .94hex .76H stl pld elastic stop nut 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 507 HOSE, oil drain assy 20 in (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 165 271 VALVE, oil drain 3/8-18NPTF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 176 529 FITTING, hose brs barbed fem 1/2tbg x 3/8NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 113 854 HOSE, SAE .500 ID x .780 OD xc oil (order by ft) 2ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 176 528 FITTING, hose brs barbed elbow fem 1/2 tbg x 1/2 NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 173 336 FITTING, adapter oil drain 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

68 191 816 BRACKET, mtg fuel filter/solenoid (Deutz F4L2011 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 192 750 BASE, fuel filter w/adapter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

70 145 282 FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 107 816 HOSE, SAE .250 ID x .500 OD xc oil (order by ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134 835 HOSE, SAE .312 ID X .560 OD X 31.000 (order by ft) 4.5ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 *192 744 FILTER, fuel spin-on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 190 992 KEEPER, latch engine access door 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 190 076 CHANNEL, stiffener engine access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 ♦202 635 CHANNEL, stiffener engine access e-coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 199 592 LATCH, paddle series 20 (black) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 200 444 LABEL, diesel engine maintenance Deutz (Wordless Label) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 +200 989 DOOR, engine access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 +210 736 DOOR, engine access ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 189 975 HINGE, door access 180deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 208 141 STOP, door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 189 826 PANEL, rocker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Quantity

Figure 15-1. Main Assembly (Continued)

80 199 298 PANEL, rocker ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 189 827 PANEL, gen RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 199 300 PANEL, gen RH ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 191 626 BUMPER, door engine access 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 189 245 TANK, fuel 23gal (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 124 253 BUSHING, tank fuel 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

85 189 912 FITTING, stl barbed elbow w/.047 in orf zinc pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 189 909 FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 189 913 FITTING, stl barbed elbow zinc pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 190 142 SENDER, fuel gauge 9.7500 deep tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 189 910 FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 189 908 VALVE, drain fuel 180deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91 181 572 BUSHING, tank fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 191 446 EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) 6ft. . . . . . . . . . . . . . . . . . . . . . . . . .

93 191 897 BRACKET, mtg unit 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 191 512 BRACKET, hold down fuel tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 190 250 LABEL, warning do not weld on base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 200 864 LABEL, warning do not weld on base (Wordless Label) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96 190 179 PANEL, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

97 R4

191 292 RESISTOR, WW fxd 375W 50 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

98 R2 189 699 RESISTOR, WW tap 375W 10 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 R3

C

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

C

100 Figure 15-2, Figure 15-3 CONTROL BOX ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 189 731 FIREWALL, lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 Figure 15-7 MAIN RECTIFIER ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 191 448 TOP, cover front upright 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 ♦199 305 TOP, cover front upright ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 +201 750 UPRIGHT, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 ♦+202 637 UPRIGHT, front ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105 134 792 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105 176 105 LABEL, warning general precautionary (Wordless Label) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106 Figure 15-4, Figure 15-5 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107 ♦202130 XFMR, current sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108
109 PC1

C

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

V

C

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

V

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

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

202 031 KIT, label (includes safety and informational labels) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 062 KIT, label (includes safety and informational labels) (Wordless Labels) 1. . . . . . . . . . . . . . . . . . . . . . .

110 199 063 ENGINE, Deutz dsl elec F3L912 d0392−166/00 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111 *064 677 FILTER, oil (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112 *066 271 BELT, blower (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 *195 745 SWITCH, pressure oil 1.5 bar nc cont 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 *195 746 SENDER, coolant temp & 130 degee C switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115 194 135 BACKPLATE, Deutz F3L912 engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116 194 572 SUPPORT, front engine (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

117 FS1 141 346 SHUTDOWN KIT, engine (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

118 118 452 FTG, adapter oil drain (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

119 193 313 MANIFOLD, exhaust muffler (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 194 496 BAFFLE, lower air outlet (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121 194 497 BAFFLE, upper air outlet (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

122 194 500 BAFFLE, air intake (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

123 194 485 HOSE, air cleaner (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124 +201 714 BOX, air intake (Deutz F3L912 engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-495 Page 94

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