Miller Electric Big Blue 600 X, Big Blue 500 PT User Manual

OM-4429 2216 138H

2007−05

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 500 PT



Big Blue 600 X

(Perkins Turbo-Powered)

Visit our website at

www.MillerWelds.com

File: Engine Drive

From Miller to You

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

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

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

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

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

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

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

Working as hard as you do

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

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

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

Mil_Thank 4/05

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

4-6. Duty Cycle And Overheating 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

5-1. Installing Welding Generator 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

5-6. Connecting The Battery 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Engine Prestart Checks 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Connecting To Weld Output Terminals 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models 27 . . . . . . . . . . . . . . . . . . . . .

5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

8-3. Optional Generator Power Receptacles 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

9-1. Maintenance Label 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

9-3. Servicing Air Cleaner 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-5. Checking Generator Brushes 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-6. Servicing Fuel And Lubrication Systems 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-7. Overload Protection 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-8. Troubleshooting 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − ELECTRICAL DIAGRAMS 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − RUN-IN PROCEDURE 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. Wetstacking 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-2. Run-In Procedure Using Load Bank 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-3. Run-In Procedure Using Resistance Grid 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − GENERATOR POWER GUIDELINES 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − PARTS LIST 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom_2007−04

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

1-1. Symbol Usage

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

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

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

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

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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

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

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

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

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

there is a danger of falling.

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

unit.

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

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

 Disconnect input power or stop engine before installing or

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

 Properly install and ground this equipment according to its

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

 Indicates special instructions.

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

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

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

 When making input connections, attach proper grounding conduc-

tor first − double-check connections.

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

and sparks.

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

replace cord immediately if damaged — bare wiring can kill.

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

with a separate cable.

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

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

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

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

or worktable as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop­ping engine.

 Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

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

ment.

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

lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

 Welding, chipping, wire brushing, and grinding

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

 Wear approved safety glasses with side shields even under your

welding helmet.

OM-4429 Page 1

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

 Keep your head out of the fumes. Do not breathe the fumes.
 If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

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

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

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

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

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

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

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

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

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

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

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

gas, or liquid vapors (such as gasoline).

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

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

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

contact tip when not in use.

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

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

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

from your person before doing any welding.

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

glowing embers, and flames.

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

pass them.

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

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

NOISE can damage hearing.

BUILDUP OF GAS can injure or kill.

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

proved air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays that

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

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

 Wear approved safety glasses with side shields under your

helmet.

 Use protective screens or barriers to protect others from flash,

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

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

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

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums,

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

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

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

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

 Do not weld where flying sparks can strike flammable material.
 Protect yourself and others from flying sparks and hot metal.
 Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

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

cause fire on the hidden side.

Noise from some processes or equipment can dam­age hearing.

 Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect Implanted
Medical Devices.

 Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

 Implanted Medical Device wearers should consult their doctor

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

CYLINDERS can explode if damaged.

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

 Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

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

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

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

use or connected for use.

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

ber of persons to lift and move cylinders.

 Read and follow instructions on compressed gas cylinders,

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

OM-4429 Page 2

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

 Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

 Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

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

FUEL can cause fire or explosion.

 Stop engine and let it cool off before checking or

adding fuel.

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

any sparks or open flames.

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

MOVING PARTS can cause injury.

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

closed and securely in place.

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

guards for maintenance and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

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

parts.

 Reinstall doors, panels, covers, or guards when servicing is

finished and before starting engine.

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

keep engine from kicking back or starting.

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

components.

STEAM AND HOT COOLANT can burn.

 If possible, check coolant level when engine is

cold to avoid scalding.

 Always check coolant level at overflow tank, if

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

 If the engine is warm, checking is needed, and there is no over-

flow tank, follow the next two statements.

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

completely removing cap.

Using a generator indoors CAN KILL
YOU IN MINUTES.

 Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

 NEVER use inside a home or garage, EVEN IF

doors and windows are open.

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

vents.

BATTERY ACID can BURN SKIN and EYES.

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

ENGINE HEAT can cause fire.

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

surfaces or flammables.

 Keep exhaust and exhaust pipes way from

flammables.

HOT PARTS can cause severe burns.

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

ment.

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

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

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can
cause serious injury or death.

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

COMPRESSED AIR can cause injury.

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

EXHAUST SPARKS can cause fire.

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

required areas — see applicable codes.

TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.

 Release air pressure from tools and system be-

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

OM-4429 Page 3

HOT METAL from air arc cutting and

READ INSTRUCTIONS.

gouging can cause fire or explosion.

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

HOT PARTS can cause burns and injury.

 Do not touch hot compressor or air system

parts.

 Let system cool down before touching or ser-

vicing.

 Read Owner’s Manual before using or servic-

ing unit.

 Stop engine and release air pressure before

servicing.

 Use only genuine replacement parts from the

manufacturer.

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

 Do not install unit near flammables.

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

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

FALLING UNIT can cause injury.

 Use lifting eye to lift unit and properly installed

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

 Lift and support unit only with proper equipment

and correct procedures.

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

extend beyond opposite side of unit.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or

stopping engine.

 Do not let low voltage and frequency caused by

low engine speed damage electric motors.

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

where applicable.

FLYING SPARKS can cause injury.

WELDING WIRE can cause injury.

 Do not press gun trigger until instructed to do

so.

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

other people, or any metal when threading
welding wire.

OVERUSE can cause OVERHEATING.

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

starting to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

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

according to instructions supplied with trailer.

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

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

 Sparks can cause fires — keep flammables away.

MOVING PARTS can cause injury.

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

rolls.

OM-4429 Page 4

READ INSTRUCTIONS.

 Read Owner’s Manual before using or servic-

ing unit.

 Use only genuine replacement parts from the

manufacturer.

 Perform engine and air compressor mainte-

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

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

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

navigation, safety services, computers, and
communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

 The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the
installation.

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

equipment at once.

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

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

1-6. California Proposition 65 Warnings

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

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

 Electromagnetic energy can interfere with

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

 Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

 Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

 Be sure this welding machine is installed and grounded

according to this manual.

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

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

For Gasoline Engines:

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

For Diesel Engines:

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

1-7. Principal Safety Standards

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

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

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

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

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

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

1-8. EMF Information

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

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

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

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

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

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

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

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

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

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

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

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

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

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

About Implanted Medical Devices:

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

OM-4429 Page 5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_2007−04fre

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

2-1. Signification des symboles

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

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

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

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

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

L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.

Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.

L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce moment-là.
En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en
contact avec le fil de soudage sont sous tension. Des matériels mal
installés ou mal mis à la terre présentent un danger.

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

tant pas de trous.

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

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

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

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

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

MENT si le procédé de soudage le demande.

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

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

 Des précautions de sécurité supplémentaires sont requises dans

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

OM-4429 Page 6

 Indique des instructions spécifiques.

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

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

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

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

1910.147 (voir normes de sécurité).

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

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

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

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

 En effectuant les raccordements d’entrée fixer d’abord le conduc-

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

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

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

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

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

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

sante ou mal épissés.

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

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

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

la terre ou une électrode provenant d’une autre machine.

 Ne pas toucher des porte électrodes connectés à deux machines

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

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

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

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

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

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

contact avec tout objet métallique.

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

 Couper l’alimentation du poste et décharger les condensateurs

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

DES PIÈCES CHAUDES peuvent

-

e

­r

e

s

u

e

n

o
e

e

e

u
n

e

f

e

c

e

provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

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

DES PIECES DE METAL ou DES SA­LETES peuvent provoquer des bles­sures dans les yeux.

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

fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.

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

facial.

LES FUMÉES ET LES GAZ peuvent êtr
dangereux.

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

 Eloigner votre tête des fumées. Ne pas respirer les fumées.
 À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

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

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

approuvé.

 Lire et comprendre les spécifications de sécurité des matériaux

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

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

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

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

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

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

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

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

 Fermer l’alimentation du gaz protecteur en cas d

non utilisation.

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

respirateur d’adduction d’air homologué.

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

Le rayonnement de l’arc du procédé de soudag

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

 Porter un casque de soudage approuvé muni de verres filtrants

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

 Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

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

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

 Porter des vêtements confectionnés avec des matières résistan-

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

LE SOUDAGE peut provoquer un in
cendie ou une explosion.

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

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

 Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.

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

sur des substances inflammables.

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

de métal chaud.

 Des étincelles et des matériaux chauds du soudage peuvent

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

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

proximité.

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

peut déclencher un incendie de l’autre côté.

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

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

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

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

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

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

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

lées.

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

électrode ou couper le fil à la pointe de contact.

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

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

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

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

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

ce d’étincelles incandescentes ni de flammes.

 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

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

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

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affe

l’ouïe.

 Porter des protections approuvés pour les or

les si le niveau sonore est trop élevé.

OM-4429 Page 7

LES CHAMPS MAGNETIQUES peuv-

a

a

a
n

e

s
s

o

e

s

e

t

o

,

-

e

­r

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

ent affecter des implants médicaux.

 Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

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

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

 Tenir les bouteilles éloignées des circuits de soudage ou autres

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

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

Si des BOUTEILLES sont endomm
gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du g

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

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

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

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

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

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

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

2-3. Dangers existant en relation avec le moteur

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

circuits électriques.

une bouteille.

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

bouteille.

d’utilisation ou de branchement de la bouteille.

samment de personnes pour soulever et déplacer les bouteilles.

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

L’EXPLOSION DE LA BATTERIE peu
RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gant

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

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

de batterie.

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

la batterie.

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

des véhicules de démarrage rapide.

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

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

dernier lieu.

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

 Arrêter le moteur avant de vérifier le niveau d

carburant ou de faire le plein.

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

ou d’une flamme nue.

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

pour son expansion.

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

carburant renversé avant de faire démarrer le moteur.

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

remplissage.

DES ORGANES MOBILES peuvent pr
voquer des blessures.

 Ne pas approcher les mains des ventilateurs

courroies et autres pièces en mouvement.

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

couvrements et dispositifs de protection.

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

OM-4429 Page 8

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

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

 Pour empêcher tout démarrage accidentel pendant les travaux

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

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

des organes mobiles.

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

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

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

mise en route accidentelle du moteur.

 Bloquer le volant moteur pour éviter sa rotation lors d’une interven-

tion sur le générateur.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

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

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

 Il est préférable de vérifier le liquide de refroi-

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

 Toujours vérifier le niveau de liquide de refroidissement dans le

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

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

me suivant.

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

le bouchon du radiateur.

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

avant d’enlever le bouchon.

L’utilisation d’un groupe autonome

t

,

e

-

e

s

r

u

à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.

 Les fumées d’un groupe autonome contient du

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

 JAMAIS utiliser dans une maison ou garage,

même avec les portes et fenêtres ouvertes.

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

bouches aération.

LA CHALEUR DU MOTEUR peut pro­voquer un incendie.

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

proximité de surfaces inflammables.

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

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

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

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

2-4. Dangers liés à l’air comprimé

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

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

page, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer
des blessures.

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

soi-même.

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

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

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

LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du

moteur de provoquer un incendie.

 Utiliser uniquement un pare-étincelles

approuvé − voir codes en vigueur.

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

 Ne pas couper ou gouger à proximité de pro-

duits inflammables.

 Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provo­quer des brûlures et blessures.

 Ne pas toucher le compresseur ou d’autres

éléments du circuit air comprimé chauds.

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

maintenance.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 Arrêter le moteur et relâcher la pression avant

d’effectuer la maintenance.

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

constructeur.

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

Risque D’INCENDIE OU D’EXPLO­SION.

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

à proximité de surfaces inflammables.

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

duits inflammables.

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

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

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

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

LA CHUTE DE L’APPAREIL peut blesser.

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

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

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

l’équipement approprié et en suivant le
procédures adéquates.

OM-4429 Page 9

LE SURCHAUFFEMENT peut endom-

e

-

-

,

t

a

-

n

u

-

mager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant d

démarrer ou d’arrêter le moteur.

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

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

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

s’il y a lieu.

LES ÉTINCELLES VOLANTES ris­quent de provoquer des blessures.

 Porter un écran facial pour protéger le visage e

les yeux.

 Affûter l’électrode au tungstène uniquement à l

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

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

stance inflammable.

DES ORGANES MOBILES peuvent
provoquer des blessures.

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

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

 Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

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

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

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter le fac-

teur de marche nominal.

 Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

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

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les
circuits imprimés.

 Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques pour stocker,

déplacer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut
entraîner des blessures.

 Utiliser les supports de la remorque ou des

blocs pour soutenir le poids.

 Installer convenablement le poste sur la remor-

que comme indiqué dans le manuel s’y rappor­tant.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

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

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

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

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

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

 Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’instal­lation.

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

cien qualifié les interférences résultant de l’installation.

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

pareil.

 Effectuer régulièrement le contrôle et l’entretien de l’installation.
 Maintenir soigneusement fermés les portes et les panneaux des

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

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

 L’énergie électromagnétique risque de provo-

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

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

compatible électromagnétiquement.

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

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

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

ment électronique sensible.

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

conformément à ce mode d’emploi.

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

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

OM-4429 Page 10

2-6. Proposition californienne 65 Avertissements

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

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

2-7. Principales normes de sécurité

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

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

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

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

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

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

Pour les moteurs à essence :

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

Pour les moteurs diesel :

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

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

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

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

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

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

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

2-8. Information EMF

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

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

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

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

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

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

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

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

En ce qui concerne les implants médicaux :

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

OM-4429 Page 11

SECTION 3 − DEFINITIONS

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

1

2

3

4

5

0 − 50 h Std.

50 h Std.

+

DIESEL

200A

S-177 571

+

0 − 200A

1 Remove unit from shipping

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

2 Read Owner’s Manual. Read

labels on unit.

3 Use Diesel Fuel only, and fill

fuel tank. Leave room for
expansion.

4 Warning! Watch Out! There

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

5 Check oil level. Add oil if

necessary.

6 During the first 50 hours of

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

7 After the first 50 hours of

operation, change the oil and
oil filter.

API CD-MIL L 2104D,

CD/SE, CD/SF

3/96

OM-4429 Page 12

3-2. Manufacturer’s Rating Labels

CC Models CC/CV Models

OM-4429 Page 13

3-3. Symbols And Definitions

 Some symbols are found only on CE products.

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

3

U

I

2

Seconds

Circuit Protector

Engine-Driven,

Three-Phase

Alternator With

Rectifier

Conventional
Load Voltage

Current

1

Hz

n

I

2

Single Phase

Do Not Switch
While Welding

Hertz

Rated Load

Speed

Rated Welding

Current

OM-4429 Page 14

SECTION 4 − SPECIFICATIONS

Three-Phase Generator

25 gal

! Do not mo

e or operate unit where it could

B C

°

H

20°

F

E

4-1. Weld, Power, And Engine Specifications

Maximum

Welding

Mode

CC/DC

CV/DC

(CC/CV

Models

Only)

4-2. Dimensions, Weights, And Operating Angles

Height

Width

Depth 65-1/8 in (1654 mm)

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

E 27-1/2 in (699 mm)

F 1 in (25 mm)

G 29-13/16 in (757 mm)

H

* With mounting brackets in center

position. Dimensions vary with
location of mounting brackets.

w/ Perkins

404-22T

Weld Output

Range

65 − 600 A

(CC Models)

20 − 600 A

(CC/CV Models)

14 − 40 V

Dimensions

60 in (1524 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: 1700 lb (771 kg)

w/fuel: 1875 lb (850 kg)

Lifting Eye Weight Rating:

2500 lb (1134 kg) Maximum

Rated Welding

Output

500 A, 40 Volts DC,

100% Duty Cycle

550 A, 42 Volts DC,

60% Duty Cycle

600 A,

30 Volts DC (CC),

40% Duty Cycle

BAC

D

Open-

Circuit

Voltage

95

56

Three-Phase Generator

Single-Phase/Three-Phase,

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

*In Addition To Standard

4 kVA/kW Generator Power

G

E

Generator Power

Rating

Standard

Single-Phase,

4 kVA/kW, 34/17 A,

120/240 V AC,

50/60 Hz

Option*

120/240 VAC, 60 Hz

! Do not exceed tilt angles or engine could

be damaged or unit could tip.

tip.

20°

802 161-A

Engine

Perkins

Perkins 404C-22T

Water-Cooled,
Four-Cylinder,

47 HP Turbocharged

Diesel Engine

v

Fuel

Capacity

25 gal
(95 L)

°

30

30°

°

OM-4429 Page 15

4-3. Volt-Ampere Curves For CC Models

100

80

60

40

DC VOLTS

20

0

0 100 200 300 400 500 600 700 800 900

DC AMPERES

Ranges
300−Max

185−425
125−320
85−190
55−90

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

Notes

203 412

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4429 Page 16

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

A. Stick Mode

100

80

60

40

DC VOLTS

20

0

0 100 200 300 400 500 600 700 800 900

B. MIG Mode

100

80

DC AMPERES

Ranges

275−Max
150−525
110−390
80−240

50−125

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

1000

60

40

DC VOLTS

20

0

0 100 200 300 400 500 600 700 800 900 1000

C. TIG Mode

100

80

60

40

DC VOLTS

MAX

MIN

DC AMPERES

Ranges

50−440
35−320
25−215
15−115

20

0

0 100 200 300 400 500

DC AMPERES

217 811 / 203 415 / 217 810

OM-4429 Page 17

4-5. Fuel Consumption

2.50

2.25

2.00

1.75

1.50

1.25

1.00

U.S. GAL./HR.

0.75

0.50

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

0.25

IDLE

0

0 50 100 150 200 250 300 350 400 450 500 550 600

DC WELD AMPERES AT 100% DUTY CYCLE

4-6. Duty Cycle And Overheating

100% Duty Cycle At 400 Amperes

Continuous Welding

215 082−A

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

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

OM-4429 Page 18

202 356

4-7. AC Generator Power Curve

300

150

250

125

200

100

150

75

AC VOLTS

100

50

50

25

0

0

0 5 10 15 20 25 30

AC AMPERES IN 240V MODE

0102030405060

AC AMPERES IN 120V MODE

4-8. Optional Three-Phase Generator Curves

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

193 018

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

AC VOLTS

200

180

0 10203040506070

AC AMPERES

197 472 / 197 473

OM-4429 Page 19

SECTION 5 − INSTALLATION

5

-1. Installing Welding Generator

! Always securely fasten weld-

ing generator onto transport

Movement

OR OR

Location/Airflow Clearance

18 in

(460 mm)

18 in

(460 mm)

OR

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

OR

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

! Always ground generator

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

! If unit does not have GFCI re-

ceptacles, use GFCI-protected
extension cord.

! Do not install unit where air

flow is restricted or engine
may overheat.

 See Section 4-2 for lifting eye rat-

ing.

 See Section 5-3 for mounting in-

formation.

Grounding:

1 Equipment Grounding Terminal

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

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

 Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

! Bed liners, shipping skids,

and some running gears insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equipment

grounding terminal to bare

metal on the vehicle frame as

shown.

Grounding

OM-4429 Page 20

GND/PE

1

2

3

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

5-2. Using Lifting Eye

1 Lifting Eye
2 Nut

1

2

3

3 Carriage Bolt
Raise lifting eye until it snaps in

place. Lower lifting eye when not
needed.

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

Tools Needed:

Notes

Ref. 802 311

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4429 Page 21

5-3. Mounting Welding Generator

Supporting The Unit

Using Mounting Brackets

! Do not weld on base. Weld-

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

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

2

OR

1

1

2

supports to adequately support unit
and prevent damage to base.

Mounting Surface:

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

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

3 1/2 in Bolt And Washer

(Minimum − Not Supplied)

4 3/8-16 x 1 in Screws

(Supplied)

To Bolt Unit In Place:

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

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

To Weld Unit In Place:

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

at the four

Tools Needed:

OM-4429 Page 22

9/16 in

Welding Unit In Place

Bolting Unit In Place

2

4

3

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

5-4. Installing Exhaust Pipe

! Stop engine and let cool.

 Point exhaust pipe in desired di-

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

Tools Needed:

1/2 in

Notes

Ref. 803 604 / Ref. 215 158

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4429 Page 23

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

3

2

1

4

! Always wear a face shield,

rubber gloves and protective
clothing when working on a
battery.

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

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

bottom of well (maximum).

! Do not overfill battery cells.

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

8 Battery Charger

! Read and follow all instruc-

tions supplied with battery

charger.

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

 When electrolyte is low, add

only distilled water to cells to

maintain proper level.

5 A For 30 Minutes

Tools Needed:

30 A For 12 Minutes

5-6. Connecting The Battery

! Connect negative (−) cable last.

−

OR

+

−

drybatt1 6/05 − S-0886

 Reinstall cover after connecting battery.

+

Tools Needed:

OM-4429 Page 24

1/2 in

Ref. 215 158 / 803 605 / S-0756-C

5-7. Engine Prestart Checks

Check radiator coolant

level when fluid is low in

recovery tank.

Full

Diesel

404.22 Engine: 9.5 qt (9.01L)

Capacity:

Full

Full

Coolant Recovery Tank

Hot Full

 Check all engine fluids daily.

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

Automatic shutdown system stops engine if
oil pressure is too low, coolant temperature
is too high, or engine overspeeds.

 This unit has a low oil pressure shut-

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

Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 11.

Fuel

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

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

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

Oil

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

Coolant

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

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

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

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

Cold Full

803 603

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

Keep radiator and air intake clean and free
of dirt.

NOTICE − Incorrect engine temperature
can damage engine. Do not run engine with­out a properly working thermostat and ra­diator cap.

 To improve cold weather starting:

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

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

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

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

OM-4429 Page 25

5-8. Connecting To Weld Output Terminals

! Stop engine.

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

! Failure to properly connect weld

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

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

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

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

Stick and TIG Welding

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

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

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

MIG and FCAW Welding

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

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

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

Tools Needed:

3/4 in

6

3

4

5

Correct Installation

1

Do not place

anything between

weld cable terminal

and copper bar.

2

Incorrect Installation

OM-4429 Page 26

803 602 / 803 778-A

5-9. Selecting Weld Cable Sizes*

100 ft (30 m) or Less

Weld Output

Terminals

! Stop engine before

connecting to weld
output terminals.

! Do not use worn, dam-

aged, undersized, or
poorly spliced cables.

Welding

Amperes

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

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

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

10 − 60%

Duty

Cycle

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

Not Exceeding***

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

60 − 100%

Duty

10 − 100% Duty Cycle

Cycle

400 ft

(120 m)

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

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

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

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

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

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

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

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

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

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

1 Remote Amperage Adjust

Receptacle RC13
Connect optional remote control to

RC13 (see Section 6-3).

1

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

OM-4429 Page 27

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

24 VOLTS AC

OUTPU

distance remote

OUTPUT

Socket* Socket Information

A 24 volts ac. Protected by sup-

24 VOLTS AC

B Contact closure to A completes

C Output to remote control:+10

plementary protector CB5.

24 volt ac contactor control
circuit.

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

New! LDR-14 long

distance remote

(includes 120 V

receptacle)

*The remaining sockets are not used.

OR

Ref. 803 602

REMOTE

D Remote control circuit common.

T

CONTROL

115 VOLTS AC

GND

NEUTRAL G Circuit common for 24 and 115

E DC input command signal: 0 to

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

115 volts, 10 amperes, 60 Hz
ac. Protected by supplementary

I

protector CB6.

Contact closure to I completes
115 volt ac contactor control

J

circuit.

K Chassis common.

volt ac circuit.

OM-4429 Page 28

Notes

Start Your Professional

Welding Career Now!

400 Trade Square East, Troy, Ohio 45373

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

Over 80,000 trained

since 1930!

Notes

OM-4429 Page 29

SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS

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

81314976

3

4

5

OM-4429 Page 30

12

10

11

1

2

215 663 / 803 602

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

Engine Starting Controls

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

weather starting (see starting instructions fol­lowing).

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

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

 If engine does not start, let engine come

to a complete stop before attempting re­start.

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

Below 325 F (05 C): push Starting Aid switch
up for 20 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.

To Stop: turn Engine Control switch to Off
position.

Engine Gauges And Meters

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

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

ning, turn Engine Control switch to Run posi­tion.

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

tor the engine charging system. The meter
should read about 14 volts dc when the en-

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

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

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

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

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

Weld Controls

 Max OCV Control Circuit: This unit has

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

The max OCV circuit is disabled when
the Stick/TIG Selection switch is in
Scratch Start TIG position (see item 10).

8 Ampere Range Switch

NOTICE − Do not switch under load.

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

9 Amperage Adjust Control
Control adjusts amperage within range se-

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

 The numbers around the control are for

reference only and do not represent an
actual percentage value.

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

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

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

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

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

11 Amperage Adjust Switch And Remote

Amperage Adjust Receptacle

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

12 Polarity Switch (Optional)

NOTICE − Do not switch under load.

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

Weld Meters

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

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

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

unit.

OM-4429 Page 31

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

1

1 Remote Amperage Adjust

Receptacle RC13
Connect optional remote control to

RC13 (see Section 5-10).

Example: Combination Remote Amperage Control (Stick)

6-4. Weld Control/Arc Condition Information Label

In Example:

Range = 115 to 330 A DC

Percentage Of Range = 50%

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

Max (240 A DC)

Min (84 A DC)

Adjust Optional Remote ControlSet Switches Set Range Set Control

Ref. 154 862-A / Ref. 181 711-A / 803 602

 Set weld controls as shown to

achieve softer or stiffer arc condi­tions for different applications.

OM-4429 Page 32

212 944-B

Notes

OM-4429 Page 33

SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS

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

9141510 76

3

4

5

2

OM-4429 Page 34

13

OR

8

12

11

1

215 664 / 802 602

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

Engine Starting Controls

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

weather starting (see starting instructions fol­lowing).

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

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

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

To Start:

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

 If engine does not start, let engine come

to a complete stop before attempting re­start.

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

Below 325 F (05 C): push Starting Aid switch
up for 20 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.

To Stop: turn Engine Control switch to Off
position.

Engine Gauges And Meters

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

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

ning, turn Engine Control switch to Run posi­tion

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

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

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

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

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

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

Weld Controls

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

switch information.
9 Ampere Range Switch

NOTICE − Do not switch under load.

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

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

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

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

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

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

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

 The numbers around the control are for

reference only and do not represent an
actual percentage value.

11 Voltage/Amperage Adjust Switch And

Remote 14 Receptacle

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

12 Polarity Switch (Optional)

NOTICE − Do not switch under load.

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

13 Polarity/AC Switch (Optional)

! Electric shock can kill.
! Do not use AC output in damp areas,

if movement is confined, or if there is
a danger of falling.

! Use AC output ONLY if required for the

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

NOTICE − Do not switch under load.

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

Weld Meters

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

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

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

unit.

OM-4429 Page 35

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

1 Process/Contactor Switch

! Weld output terminals are ener-

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

! DC voltage is still present at the

weld terminals when Process/

1

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

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

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

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

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

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

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

 Place switch in Weld Terminals Al-

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

 The engine auto idle option does

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

Process/Contactor Switch Settings

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

Remote On/Off Switch Re-

quired − TIG, HF Required

Or Scratch Start TIG

Remote On/Off Switch

Required − Stick

Remote On/Off Switch
Required − CV Feeder

Using Remote

Weld Terminals Always On −

Wire

Weld Terminals Always On −

Stick

Weld Terminals Always On −

TIG, Scratch Start

OM-4429 Page 36

GTAW With HF Unit, Pulsing

Device, Or Remote Control

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

MIG (GMAW) At Remote 14 Receptacle Active

MIG (GMAW) Electrode Hot Active

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting

And Gouging

TIG Scratch Start (GTAW) Electrode Hot Active

At Remote 14 Receptacle Not Active

Electrode Hot Active

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

1 Remote 14 Receptacle RC14
Connect optional remote control to

RC14 (see Section 5-11).

1

Example: Combination Remote Amperage Control (Stick)

Set V/A

Adjust Switch

Example: Combination Remote Amperage Control (TIG)

Set Remote

Process

Set Range Control Not

Used In Remote

Stick Mode

Process = Stick (Using Remote On/Off)

In Example:

Range = 110 to 390 A DC

Min = 110 A DC

Max = 390 A DC

Max (390 A DC)

Min (110 A DC)

Adjust Optional Remote Control

In Example:

Process = TIG (Using Remote On/Off)

Range = 35 to 320 A DC

Percentage Of Range = 50%

Min = 35 A DC

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

Set V/A

Adjust Switch

Set Remote

Process

Set Range Set Control

Max (178 A DC)

Min (35 A DC)

Adjust Optional Remote Control

0774 / Ref. 215 664 / Ref. 803 602

OM-4429 Page 37

SECTION 8 − OPERATING AUXILIARY EQUIPMENT

8-1. 120 Volt And 240 Volt Receptacles

1

3

4

1 120 V 20 A AC GFCI

Receptacle GFCI1
2 240 V 30 A AC Twistlock

Receptacle RC1
Receptacles supply 60 Hz single-

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

2

Reset button pops out and
receptacle does not work. Check
for faulty tools plugged in
receptacle. Press button to reset
GFCI1.

 At least once a month, run en-

gine at weld/power speed and

press test button to verify GFCI

is working properly.

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

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

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

 If a supplementary protector

continues to open, contact

Factory Authorized Service

Agent.

 Generator power is not af-

fected by weld output.

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

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

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

4.0 kVA/kW

OM-4429 Page 38

191 624-A

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

 Place Process/Contactor switch

in Weld Terminals Always On ­Stick position when using three-

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

phase generator (see Section
7-3).

Single-Phase Generator Power

1 120/240 V 50 A Receptacle

RC5

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

2 Supplementary Protector CB7
Supplementary protector CB7 pro-

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

Three-Phase Generator Power

! Stop engine.
! Power and weld outputs are

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 12).

Remove generator power panel
mounting screws. Tilt panel forward.

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

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

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

Lead 42 connects to front panel
Ground stud.

11 User-Supplied Leads
12 Supplementary Protector CB7

User Terminals
Connect user-supplied leads to ter-

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

 Supplementary protector CB7

protects single-phase receptacle

RC5 and the load wires from

overload. If CB7 opens, all gener-

ator output stops and the recep-

tacle does not work.

Reinstall generator power panel.

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

OM-4429 Page 39

8-3. Optional Generator Power Receptacles

European Receptacle

5

6

Australian Receptacle

5

6

South African Receptacle

5

6

1

1 120 V 20 A AC GFCI

Receptacle GFCI1

2 240 V 16 A AC European

Receptacle RC1

2

3 240 V 15 A AC Australian

Receptacle RC1

4 240 V 15 A AC South African

Receptacle RC1

Receptacles supply 60 Hz 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.

31

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

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

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

 If a supplementary protector

continues to open, contact
Factory Authorized Service
Agent.

 Generator power is not af-

fected by weld output.

41

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-4429 Page 40

191 624

SECTION 9 − MAINTENANCE & TROUBLESHOOTING

9-1. Maintenance Label

OM-4429 Page 41

9-2. Routine Maintenance

Recycle engine

fluids.

! Stop engine before maintaining.

 See Engine Manual and Maintenance Label

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

Every

8

Hours

Every

50

Hours

Every

100

Hours

Every

250

Hours

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

FUEL

WATER

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

 Coolant Level

 Weld Terminals

 Battery Terminals  Air Cleaner Hoses  Air Cleaner Element

1/2 in.

(13 mm)

Reference

Section 5-7,
9-6

Section 9-3

Engine
Manual,
Section 9-4

Every

500

Hours

Every

1000

Hours

Every

2000

Hours

 Unreadable Labels  Fan Belt Tension Spark Arrestor

 Weld Cables  Oil  Oil Filter

OR

SLUDGE

Radiator Fluid Level  Inside Unit  FuelFilter  Drain Sludge

 Slip Rings*
 Brushes*

 Injectors*

Valve Clearance*

FUEL

Section 9-6

Section 5-7,
9-5, 9-6,
and Engine
Manual

OM-4429 Page 42

9-3. Servicing Air Cleaner

Keep nozzle

2 in (51 mm)

from element.

Blow Inspect

Optional

! Stop engine.

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

2

41 3

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

 The air cleaner primary element can

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

5

to clean or replace the primary ele­ment.

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

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

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

To clean air filter:

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

NOTICE − Do not clean housing with air
hose.

Clean primary element with compressed
air only.

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

Reinstall primary element and cap (dust
ejector down).

aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 215 158

OM-4429 Page 43

9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler

2

1

! Stop engine and let cool.

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

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

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

! Stop engine and let cool.

Reinstall cleanout plug.

Tools Needed:

3/8 in

9-5. Checking Generator Brushes

Replace

Damaged Brushes

803 656 / Ref. 215 158

! Stop engine and let cool.

1 Generator Brush
Remove brushes from brush holder.
Replace brushes if damaged or if brush

material is at or near minimum length.

Minimum Length:

5/8 in (16 mm)

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

1

Ref. 215 664

OM-4429 Page 44

9-6. Servicing Fuel And Lubrication Systems

4

5

6

3

7

2

8

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

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

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

5 Primary Fuel Filter (Fuel/

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

To change oil and filter:

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

1

manual and engine 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.

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

Inspect fuel lines, and replace if
cracked or worn.

To replace secondary fuel filter:

See engine manual.

To drain sludge from fuel tank:

! Beware of fire. Do not smoke

and keep sparks and flames

away from drained fuel. Dis-

pose of drained fuel in an en-

vironmentally-safe manner.

Do not leave unit unattended

while draining fuel tank.

! Properly lift unit and secure

in a level position. Use ade-

quate blocks or stands to

support unit while draining

fuel tank.

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

Close door.

Tools Needed:

802 490 / Ref. 801 434

OM-4429 Page 45

9-7. Overload Protection

! Stop engine.

 When a supplementary protector,

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

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

21

9

8

7

5

4

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

(CC/CV Models Only)

5 Supplementary Protector CB6

(CC/CV Models Only)
6 Circuit Breaker CB10 (Not Shown)
7 Supplementary Protector CB11
8 Supplementary Protector CB12
9 Supplementary Protector CB13
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 weld control circuit. On
CC models, if CB11 opens the max OCV
circuit does not work and open circuit
voltage is variable at all times (see max
OCV note under Weld Controls in Section
6-2). If CB11 opens on CV models, weld
output stops (generator power is still
available).

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

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

Press button to reset.

OM-4429 Page 46

803 605

9-8. Troubleshooting

A. Welding − CC Models

Trouble Remedy

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

No weld output or generator power out­put at ac receptacles.

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

Check position of Ampere Range switch.

Check position of optional Polarity switch.

Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
control to Remote Amperage Adjust receptacle RC13 (see Sections 5-10 and 6-1).

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-10).

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

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

Disconnect equipment from generator power receptacles during start-up.

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

Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1 (see Sec­tion 9-7).

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

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Have Factory Authorized Service Agent check brushes and slip rings.

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

Check engine speed, and have Factory Authorized Service Agent adjust if necessary.

Have Factory Authorized Service Agent check OCV control circuit.

Low weld output. Check engine speed, and have Factory Authorized Service Agent adjust if necessary.

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 speed, and have Factory Authorized Service Agent adjust if necessary.

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

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

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

Place Stick/TIG switch in Stick position.

Have Factory Authorized Service Agent check control relay CR7.

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-10).

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

Repair or replace remote control device.

Have Factory Authorized Service Agent check OCV control circuit.

OM-4429 Page 47

B. Welding − CC/CV Models

Trouble Remedy

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

No weld output or generator power out­put at ac receptacles.

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

Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
On/Off Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14
(see Sections 5-11 and 7-1).

Check position of Ampere Range switch.

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

Reset supplementary protector CB11 (see Section 9-7).

Reset supplementary protector CB5 (see Section 9-7). Check for faulty remote device connected to
RC14.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).

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

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

Disconnect equipment from generator power receptacles during start-up.

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

Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1 (see Sec­tion 9-7).

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

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Have Factory Authorized Service Agent check brushes and slip rings.

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

Check engine speed, and have Factory Authorized Service Agent adjust if necessary.

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

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

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

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

Low open-circuit voltage. Check engine speed, and have Factory Authorized Service Agent adjust if necessary.

No remote fine amperage or voltage
control.

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

Check engine speed, and have Factory Authorized Service Agent adjust if necessary.

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

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

Check position of Process/Contactor switch.

Place Voltage/Amperage Adjust switch in Remote position.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).

Repair or replace remote control device.

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

Constant speed wire feeder does not
work.

OM-4429 Page 48

Reset supplementary protector CB5 or CB6 (see Section 9-7).

Trouble Remedy

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).

Repair or replace wire feeder.

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

Increase Voltage/Amperage Adjust Control setting.

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

Repair or replace remote control device.

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

C. Standard Generator Power

Trouble Remedy

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

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

High output at generator power ac re­ceptacles.

Low output at generator power ac
receptacles.

Reset receptacle supplementary protectors.

Reset GFCI receptacle.

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, diode/capacitor board D1/C1, and the rotor.

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

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

Check engine speed, and have Factory Authorized Service Agent adjust if necessary.

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

Check engine speed, and have Factory Authorized Service Agent adjust if necessary.

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

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

Trouble Remedy

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

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

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

Reset supplementary protector CB5 (see Section 9-7).

Check engine weld/power speed, and have Factory Authorized Service Agent adjust if necessary.
Have Factory Authorized Service Agent check brushes, 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 have Factory Authorized Service Agent adjust if necessary.

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

Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
PC1.

E. Engine

Trouble Remedy

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

Check battery connections and tighten if necessary.

Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-7).
Have Factory Authorized Service Agent check engine wiring harness and components.

OM-4429 Page 49

Trouble Remedy

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check control relay CR1, diode/capacitor board D8/C8, and En­gine Control switch S1.

Engine cranks but does not start. Check fuel level.

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

Have Factory Authorized Service Agent check engine wiring harness, time delay relay TD1, control
relay CR5, fuel pump, fuel solenoid FS1, and diode/capacitor board D10/C10.

Air in fuel system. See engine manual.

Engine starts, but stops after 30
seconds.

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

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

Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 5-7). Automatic shutdown system is inhibited for 30 seconds after
start-up.

Check engine speed. Overspeed shutdown automatically stops engine if speed is too high. Turn engine
off and restart to resume operation. If unit continues to overspeed and shut down, have unit checked by
a Factory Authorized Service Agent.

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

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

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

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

Have Factory Authorized Service Agent check starting aid switch and glow plugs.

temperature is too high (see Section 5-7). Automatic shutdown system is inhibited for 30 seconds after
start-up.

See engine manual.

Have Factory Authorized Service Agent check engine speed sensor.

Engine slowly stopped and cannot be
restarted.

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

Engine does not run at weld/power
speed.

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).

Check fuel level.

Check engine air and fuel filters (see Sections 9-3 and 9-6).

See engine manual.

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

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months).

Have Factory Authorized Service Agent check engine controller, throttle actuator TS1, and speed sensor.

Check for obstructed throttle actuator TS1.

Have Factory Authorized Service Agent check idle module PC7, current transformer CT1, throttle actua­tor TS1, and engine controller.

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

Check for obstructed throttle actuator.

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

OM-4429 Page 50

Have Factory Authorized Service Agent check idle module PC7, control relay CR6, throttle actuator TS1,
speed sensor, and engine controller.

Dry engine according to run-in procedure (see Section 11).

Notes

Start Your Professional

Welding Career Now!

400 Trade Square East, Troy, Ohio 45373

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

Over 80,000 trained

since 1930!

OM-4429 Page 51

SECTION 10 − ELECTRICAL DIAGRAMS

OM-4429 Page 52

Figure 10-1. Circuit Diagram For CC Welding Generator

OM-4429 Page 53

223 525-B

OM-4429 Page 54

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

OM-4429 Page 55

223 524-B

11-1. Wetstacking

1

SECTION 11 − RUN-IN PROCEDURE

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

1 Welding Generator

2

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

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

2 Engine Exhaust Pipe
Wetstacking is unburned fuel and

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

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

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

run_in1 2007−04

OM-4429 Page 56

11-2. Run-In Procedure Using Load Bank

4

2

3

Stop engine.

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

Keep exhaust and pipe away
from flammables.

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

1

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

1 Load Bank
Turn all load bank switches Off. If

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

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

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

3 Weld Cables
Connect load bank to generator

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

Start engine and run for several
minutes.

Set load bank switches and then
adjust generator A/V control so
load equals rated voltage and
current of generator (see name­plate, rating label, or the specifi­cations section in this manual).

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

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

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

Stop engine and let cool.

4 Engine Exhaust Pipe
Repeat procedure if wetstacking

is present.

S-0683

OM-4429 Page 57

11-3. Run-In Procedure Using Resistance Grid

6

2

3

4

+

5

Stop engine.

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

Keep exhaust and pipe away
from flammables.

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

1 Resistance Grid
Use grid sized for generator rated

1

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

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

3 Weld Cables
Connect grid to generator weld

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

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

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

minutes.

Set grid switches and then ad­just generator A/V control so
load equals rated voltage and
current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).

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

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

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

OM-4429 Page 58

Stop engine and let cool.

6 Engine Exhaust Pipe
Repeat procedure if wetstacking is

present.

S-0684

SECTION 12 − GENERATOR POWER GUIDELINES

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

12-1. Selecting Equipment

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

 Be sure equipment has double

1

2

3

OR

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

insulated symbol and/or word­ing on it.

! Do not use 2-prong plug un-

less equipment is double in­sulated.

12-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

2

3

! Always ground generator

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

! Also see AWS Safety &

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

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied)
3 Metal Vehicle Frame
Connect cable from equipment

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

 Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

! Bed liners, shipping skids,

and some running gear insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equip-

ment grounding terminal to

bare metal on the vehicle

frame as shown.

! If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

S-0854

OM-4429 Page 59

12-3. Grounding When Supplying Building Systems

1 2

GND/PE

2

3

1 Equipment Grounding

Terminal
2 Grounding Cable
Use #10 AWG or larger insulated

copper wire.
3 Ground Device

 Use ground device as stated in

electrical codes.

! Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

! Also see AWS Safety &

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

12-4. How Much Power Does Equipment Require?

3

2

1

3

VOLTS 115
AMPS
Hz

4.5
60

ST-800 576-B

1 Resistive Load
A light bulb is a resistive load and

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

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

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

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

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

watts.
Example 2: If three 200 watt flood

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

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

flood lamps and drill is 1120 watts.

OM-4429 Page 60

S-0623

12-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

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

Capacitor Start-Induction Run 1/3 HP 2020 720

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

1 HP 6100 1600

1-1/2 HP 8200 2200

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

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

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

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

12-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts

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

1-1/2 HP 8200 2200

2 HP 10550 2850
3 HP 15900 3900

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

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

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

OM-4429 Page 61

12-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

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

Circular Saw 6-1/2 in 500 500

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

Table Saw 9 in 4500 1500

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

8 in 3900 1400

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

1 HP 6000 1500

1-1/2 HP 8200 2200

2 HP 10500 2800

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

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

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

Metal Halide 313 250

Mercury 1000

Sodium 1400

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

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

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

2-1/2 HP 1300 1300

OM-4429 Page 62

12-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

Motor Start

Code

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

G H J K L M N P

1 Motor Start Code
2 Running Amperage

4
1
3

VOLTS AMPS

CODE 60

HP

AC MOTOR

230 2.5

M

1/4

Hz
PHASE

1

2

3 Motor HP
4 Motor Voltage
To find starting amperage:

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

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

age (see example).
Welding generator amperage out-

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

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

Starting Amperage

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

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

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

amperes.

S-0624

12-9. How Much Power Can Generator Supply?

1

2

1 Limit Load To 90% Of

Generator Output

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

2 5 Second Rule
If motor does not start within 5

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

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

OM-4429 Page 63

12-10. Typical Connections To Supply Standby Power

123

Utility

Electrical

Service

Transfer Switch

5

Essential

Loads

Fused

Disconnect

Switch

(If Required)

4

Welding

Generator

Output

! Have only qualified persons

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

! Properly install and ground

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

 Customer-supplied equipment

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

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

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

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

3 Fused Disconnect Switch
Install correct switch (customer-

supplied) if required by electrical
code.

4 Welding Generator Output
Generator output voltage and wir-

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

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

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

5 Essential Loads
Generator output may not meet the

electrical requirements of the prem­ises. If generator does not produce
enough output to meet all require­ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 12-4).

OM-4429 Page 64

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

Cord Lengths for 120 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

Current

(Amperes)

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

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

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

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

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

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

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

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

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

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

Load (Watts) 4 6 8 10 12 14

If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

Current

(Amperes)

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

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

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

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

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

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

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

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

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

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

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

*Conductor size is based on maximum 2% voltage drop

Load (Watts) 4 6 8 10 12 14

OM-4429 Page 65

 Hardware is common and

not available unless listed.

SECTION 13 − PARTS LIST

122

21

22

20

18

19

23

24

25

26

100

101

102

103

17

2

1

123

3

13

12

4

5

6

7

8

10

9

114 (Fig.13−7)

115 (CV)

116 (CV)

117

118

108 (CC)

111 (Fig. 13−2

OR Fig. 13-3

16

15

14

113

112

109 (CC)

110

121 (Fig.13−4 OR 13−5)

OM-4429 Page 66

120

119

107

Figure 13-1. Main Assembly

104

105

106

29

33

34

47

48

49

28

27

124

30

32

31

88 (Fig.13−6)

89

90

91

92

93

94

95

87

96

97

98

35

36

37

39

38

85

86

40

84

41

42

83

82

81

43

80

64
65
66

67
68
69

70

63

44

62

71

61

60

59

72

45

58

57

73

46

50

51

52

53

54

55

56

74

75

76

77

99

79

78

803 844-B

OM-4429 Page 67

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 13-1. Main Assembly

1 189 824 Panel, Gen Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ♦199 294 Panel, Gen Lh Ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 200 865 Label, CE Sound Power Level 98db (Export Models Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 +189 828 Panel, Engine Side 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦+199 301 Panel, Engine Side Ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

4Z1
4Z1

189 395 Reactor, Ac 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

C

201 520 Reactor, Ac Environmental 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V

5 206 352 Brace, Front To Center Upright 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 1T 038 621 Block, Term 30a 4 Pole Frict Term Str 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038 620 Link, Jumper Term Blk 30a 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 081 499 Bracket, Mtg Strip Terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203 260 Label, Caution Do Not Use Ether 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 T1 201 613 Transformer W/Bracket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 T1 ♦205 636 Transformer W/Bracket (Environmental Coating) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 201 697 Pan, Reactor And Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 173 352 Extrusion, Rubber Clamp/Bulb (Order By Ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 189 708 Firewall, Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 191 307 Cover, Plate 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 189 763 Bracket, Mtg Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 218 048 Hose, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 218 047 Tube, Air Intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 218 046 Hose, Air Cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 863 Clamp, Hose 1.125 − 3.000 Clp Dia 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 220 091 Hose, Sae .500 Id X .750 Od X 13.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 189 764 Air Cleaner, Intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*192 938 Filter, Air Element Primary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*♦192 939 Filter, Air Element Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 189 464 Seal, Weather Lift Eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173 909 Hose, Sae .312 Id X .560 Od X 24.000 (Order By Ft) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 201 658 Upright, Center Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 191 819 Hose, Sae .312 Id X .560 Od X 14.000 (Order By Ft) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198 584 Hose, Sae .312 Id X .560 Od X 5.000 (Order By Ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 095 636 Hose, Sae .187 Id X .41 Od X 30.000 (Order By Ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 206 297 Base, Fuel Filter W/Fittings 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 *192 744 Filter, Fuel Spin−on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 +201 934 Cover, Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 ♦+202 640 Cover, Top Ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 189 052 Grommet, Plastic Neck Filler Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 190 198 Cap, Tank Screw−on 3.500 In W/Vent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 192 041 Label, Use Diesel Fuel Only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 222 513 Label, Warning Falling Equipment Can Cause Serious 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 224 265 Label, Warning Hot Exhaust Parts Do Not Touch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 105 734 Pipe, Muffler Extension Elbow 1.750 Od 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 201 851 Cover, Radiator Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 ♦202 629 Cover, Radiator Access Ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 191 354 Support, Cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 ♦202 633 Support, Cover E−coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 010 875 Clamp, Muffler 2.000 Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 215 345 Manifold, Exhaust Muffler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 Bracket (Included With Item 37 − Manifold Muffler) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

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Figure 13-1. Main Assembly (Continued)

39 216 133 Engine, Perkins Dsl Elec 404C−22T 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*214 931 Sender, Coolant Temp & 110c N.o. Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*215 094 Switch, Oil Pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

023 562 Clamp, Hose .312 − .875 Clp Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*197 899 Filter, Oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*192 744 Filter, Fuel Spin−on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*197 997 Filter, Fuel Secondary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 214 658 Hose, Radiator Upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 218 273 Fan, Engine Cooling 15.350 Blower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 *197 944 Belt, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 202 017 Guard, Belt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 220 280 Radiator, W/Shroud (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220 281 Shroud, Radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

187 120 Cap, Radiator Pressure 14 Lb 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 201 749 Upright, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 ♦207 188 Upright, Rear Ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦207 005 Grill, Rear Panel Ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 108 081 Terminal Protector, Battery Post Mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 190 206 Cable, Bat Neg 42 In Lg No. 2 Awg W/Clamp And .375rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 190 207 Cable, Bat Pos 45 In Lg No. 1 Awg W/Clamp And .406rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 203 430 Bracket, Battery Holddown 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 190 897 Battery, Stor 12v 650crk 110rsv Gp 24 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 225 120 Label, Warning Moving Parts Can Cause Injury 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 168 385 Label, Warning Battery Explosion Can Blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 +201 183 Cover, Battery Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 ♦+202 639 Cover, Battery Access Ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 201 006 Bolt, J Stl .312−18 X 8.500 Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 225 120 Label, Warning Moving Parts Can Cause Injury 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 +215 006 Guard, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 197 496 Hose, Radiator Lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 505 Hose, Oil Drain Assy 32 In (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 165 271 Valve, Oil Drain 3/8−18nptf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

59 176 529 Fitting, Hose Brs Barbed Fem 1/2tbg X 3/8npt 1

60 113 854 Hose, Sae .500 Id X .780 Od Xc Oil (Order By Ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 Washer, Oil Drain (Available Through Engine Manufacturer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 197 196 Fitting, Adapter Oil Drain 12mm Male X 3/8 Npt Female 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 197 448 Fitting, Hose Brs Barbed Elbow M 1/2 Tbg X 3/8 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 199 849 Screw, 625−11 X 4.00hexhd Pln Gr 5 Pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 071 731 Washer, Flat .656 Id X 2.250 Od X .187t Stl Pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 197 489 Bracket, Mtg Rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 197 488 Bracket, Mtg Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 071 890 Retainer, Mount Eng/Gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 071 730 Tubing, Stl .875 Od X 12ga Wall X 2.500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 083 476 Mount, Eng/Gen Nprn .875 Id X 2.500 Od X 2.000 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 135 205 Nut, 625−11 .94hex .76h Stl Pld Elastic Stop Nut 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 190 992 Keeper, Latch Engine Access Door 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 190 076 Channel, Stiffener Engine Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 ♦202 635 Channel, Stiffener Engine Access E−coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 199 592 Latch, Paddle Series 20 (Black) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 220 539 Label, Maintenance Big Blue Perkins Series 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 +200 989 Door, Engine Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 ♦+210 736 Door, Engine Access Ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 189 975 Hinge, Door Access 180deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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77 190 190 Tank, Coolant Recovery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 208 141 Stop, Door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 189 826 Panel, Rocker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 ♦199 298 Panel, Rocker Ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 189 827 Panel, Gen Rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 199 300 Panel, Gen Rh Ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 191 626 Bumper, Door Engine Access 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 *197 997 Filter, Fuel Secondary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 Pump, Fuel (Available Through Engine Manufacturer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 173 909 Hose, Sae .312 Id X .560 Od (Order By Ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 218 222 Bracket, Mtg Fuel Filter/Pump 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 225 120 Label, Warning Moving Parts Can Cause Injury 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 095 636 Hose, Sae .187 Id X .410 Od X 30.000 (Order By Ft) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 Figure13-6 Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 218 087 Tank, Fuel (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 124 253 Bushing, Tank Fuel 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

084 173 Clamp, Hose .460 − .545clp Dia Slfttng 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91 189 912 Fitting, Stl Barbed Elbow W/.047 In Orf Zinc Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 189 909 Fitting, Stand Pipe Hose .250 X 9.260 Lg 90deg Zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 201 025 Cap, Fuel Fitting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 189 913 Fitting, Stl Barbed Elbow Zinc Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 190 142 Sender, Fuel Gauge 9.7500 Deep Tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96 189 910 Fitting, Stand Pipe Hose .3125 X 9.260 Lg 90deg Zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 181 572 Bushing, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98 189 908 Valve, Drain Fuel 180deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 191 446 Extrusion, Rubber W/Adhesive 1.000 X 1.000 D (Order By Ft) 6ft. . . . . . . . . . . . . . . . . . . . . . . . . . .

100 218 086 Bracket, Hold Down Fuel Tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 196 220 Bracket, Hold Down Fuel Tank Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 192 362 Bracket, Mtg Nyl 1/2 Conduit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 191 897 Bracket, Mtg Unit 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 +200 999 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106 ♦+203 382 Base E−coat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105 224 266 Label, Warning Do Not Weld On Base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106 190 179 Bracket, Mtg Resistor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107 R3 189 699 Resistor, Ww Tap 375w 10 Ohm W/Mtg Bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

108 R2
109 R4

189 699 Resistor, Ww Tap 375w 10 Ohm W/Mtg Bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

C

191 292 Resistor, Ww Fxd 375 W 50 Ohm W/Mtg Bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

110 191 446 Extrusion, Rubber W/Adhesive 1.000 X 1.000 D (Order By Ft) 6ft. . . . . . . . . . . . . . . . . . . . . . . . .

111 Figures 13-2, 13-3 Control Box Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112 189 731 Firewall, Lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 173 352 Extrusion, Rubber Clamp/Bulb (Order By Ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 Figure 13−7 Main Rectifier Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115 PC1
116

C

207 397 Module, Field Current Regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V

C

193 453 Bracket, Mtg Box Fcr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V

117 191 448 Top, Cover Front Upright 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

119 ♦199 305 Top, Cover Front Upright Ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

118 Not Applicable. . . . . . . . . . . . . . . . . . . . . . . . .

119 +201 750 Upright, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121 ♦+202 637 Upright, Front Ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 233 953 Label, Warning General Precautionary Csa 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121 Figures13-4, 13-5 Panel, Front W/Components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173 216 Label, Ce European Community Mark (Export Models Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

122 202 130 Xfmr, Current Sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4429 Page 70

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 13-1. Main Assembly (Continued)

123 212 944 Label, Weld Control/Arc Condition Information Label 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124 233 088 Label, Danger Using A Generator Indoors Can Kill You In Minutes (Unit) 1. . . . . . . . . . . . . . . .

190 058 Nut, .250−20 U−nut Multi−thread 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049 525 Nut, 312−18 U−nut Multi−thread 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

216 136 Kit, Label (Includes Safety & Informational Labels) (CC Models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

216 135 Kit, Label (Includes Safety & Informational Labels) (CC/CV Models) 1. . . . . . . . . . . . . . . . . . . . . . . . .

216 993 Kit, Label (Includes Safety & Informational Labels) (CC Export Models) 1. . . . . . . . . . . . . . . . . . . . . .

216 992 Kit, Label (Includes Safety & Informational Labels) (CC/CV Export Models)1. . . . . . . . . . . . . . . . . . . . .

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.

C

CC models only.

C

C

CC/CV models only.

V

♦Optional

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

OM-4429 Page 71

6

7

8

5

4

3

2

1

15

17

22

16

23

18

19

20

21

9

10

11

12

13

14

803 845-D

OM-4429 Page 72

Figure 13-2. Control Box Assembly − CC Models

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 111)

1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 046 432 HOLDER, fuse mintr .250 x 1.250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4 201 077 CONTROL BOX, lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R6 141 424 RESISTOR, ww fxd 30 w 25 ohm faston te 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 C12 191 944 CAPACITOR, polyp met film 10. uf 250 vac 10% 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 201 078 CONTROL BOX, rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CR8 197 325 RELAY, encl 12vdc spst 70a 4pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 CR1 090 104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Controller 219 848 MODULE, control governor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

LE3 204 702 CORE, torodial .187 id x .375 od x .125 thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 CR6 ♦090104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 D10/C10 189 701 DIODE/CAPACITOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CB10 190 374 CIRCUIT BREAKER, Auto Reset 12vdc 40 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 201 079 COVER, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CR5 223 710 RELAY, Encl 12vdc Dpst−no 25a 6pin Flange 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 PC7 ♦195 706 MODULE, pull to idle, two output, 7 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

18 CR4 ♦113 247 RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

19 TD1 214 928 TIMER, delay on make/break open 30 sec 12vdc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 C9 087 110 CAPACITOR, elctlt 240uf 200VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 177 136 CLAMP, capacitor 1.375dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

23 CB11, 12, 13 139 266 SUPPLEMENTARY PROTECTOR, man reset 1P 15A 250VAC 3. . . . . . . . . . . . .

♦Optional
*Recommended Spare Parts.

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

OM-4429 Page 73

4

5

6

3

2

1

19

17

16

15

18

14

13

22

21

20

11

12

7

8

9

10

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

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 111)

1 F1, F2 *085 874 FUSE, mintr cer slo-blo 10A 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 046 432 HOLDER, fuse mintr .250 x 1.250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 201 077 CONTROL BOX, lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 201 078 CONTROL BOX, rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 CR8 197 325 RELAY, encl 12vdc spst 70a 4pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 CR1 090 104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Engine Controller 219 848 MODULE, control governor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LE3 204 702 CORE, torodial .187 id x .375 od x .125 thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CR6 ♦090104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 D10/C10 189 701 DIODE/CAPACITOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CB10 190 374 CIRCUIT BREAKER, Auto Reset 12vdc 40 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 201 079 COVER, control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 CR5 223 710 RELAY, encl 12vdc dpst−no 25a 6pin flange 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 PC7 ♦195 706 MODULE, pull to idle, two output, 7 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 SR1 035 704 RECTIFIER, integ 40A 800V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CR4 ♦113 247 RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

16 PC9 192 224 CIRCUIT CARD ASSY, display 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

803 846-D

Quantity

OM-4429 Page 74

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

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

17 134 201 STAND-OFF, support pc card 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 C9 087 110 CAPACITOR, elctlt 240uf 200VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 177 136 CLAMP, capacitor 1.375dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

21 TD1 214 928 TIMER, delay on make/break open 30 sec 12vdc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 CB11, 12, 13 139 266 SUPPLEMENTARY PROTECTOR, man reset 1P 15A 250VAC 3. . . . . . . . . . . . .

♦Optional
*Recommended Spare Parts.

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

OM-4429 Page 75

 Hardware is common and

not available unless listed.

3

4

5

38

39

37

36

40

41

42

1

35

34

2

31

30

32

12

13

6

7
8

9

11

10

14

15

16

17

803 649

Item

No.

Dia.

Mkgs.

33

28

27

29

26

20

24

25

18

19

22

23

Figure 13-4. Panel, Front w/Components − CC Models

Part

No.

Description

Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 121)

21

Quantity

1 215 070 PLATE SCREENED, ident control rating; when ordering this item,. . . . . . . . . . . . . . . . . .

the nameplate should also be ordered) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 NAMEPLATE, screened (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4429 Page 76

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 13-4. Panel, Front w/Components − CC Models (Continued)

3 215 014 PANEL, engine/weld control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦217 883 PANEL, engine/weld control ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S3 208278 SWITCH, range/changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R1 188 635 RHEOSTAT, WW 300W 34 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 202 209 SPACER, nylon 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 S6 011 622 SWITCH, tgl DPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 S5 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr 1. . . . . . . . . . . . . . . . . . . . . . . . . .

9 RC13 032 897 RECEPTACLE, twlk grd 2P3W 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 S1 212 436 SWITCH, ignition 4 position w/handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 S2 021 467 SWITCH, tgl spst 3a 250v off−none−(on) spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 553 CLIP, circuit breaker retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 CB1 201 083 SUPPLEMENTARY PROTECTOR, man reset 2P 20 A, 250VAC 1. . . . . . . . . . . . . . . . . .

13 CB2 093 996 SUPPLEMENTARY PROTECTOR, man reset 1P 20A 250VAC frict 3. . . . . . . . . . . . . . . .

14 GFCI1 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

15 RC1 147 632 RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 RC1 176 355 RECEPTACLE, str 2p3w 16a 220v flange mtg (export models only) 1. . . . . . . . . . . . . .

16 190 861 LABEL, warning electric shock and moving parts etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 +215 347 PANEL, gen pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 ♦+215 405 PANEL, gen pwr ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 ♦+215 403 PANEL, gen pwr (export models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 083 030 STUD, brs .250−20 x 1.750 w/hex collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 601 836 NUT, 250−20 .50hex .19h brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 ♦196 073 LABEL, do not switch while welding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 S12 ♦195 825 SWITCH, polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 201 125 PANEL, mtg terminal pwr output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 ♦199 303 PANEL, mtg terminal pwr output ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 735 WASHER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 181 169 SPACER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 186 621 BOOT, generic output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 ♦059 773 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

27 ♦010 647 PIN, spring cs .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 209 056 COVER, receptacle w/gasket 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 206 795 BOOT, circuit breaker clear hex nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 021 385 BOOT, toggle switch lever 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 201 045 COVER, receptacle twistlock 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 ♦193 228 METER, Volt Dc 8− 18 Scale 2.250 In Black Face 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 FUEL 192 265 GAUGE, fuel elec switch w/o sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 HM 210 424 METER, hour 12-24VDC 2.25dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 217 084 GAUGE, Coolant Temp 0− 300 Deg F Electric 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197 798 SENDER, Coolant Temp 300 Deg F M16 X 1.5 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 217 083 GAUGE, Pressure Oil 0−100 Psi Electric 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 230 SENDER, Pressure Oil 0− 100 Psi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 ♦164 873 VOLT METER, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 ♦164 874 AMMETER, W/Leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 189 161 HANDLE, switch range 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 010 647 PIN, spring CS .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 019 602 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

024 103 BLANK, snap−in nyl .750 mtg hole black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

OM-4429 Page 77

 Hardware is common and

not available unless listed.

4

3

5

55

54

56

53

52

51

57

58

50

1

49

48

43

47

46

2

33

45

44

32

34

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6

28

7

8

9

10

11

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13

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3940

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37

Figure 13-5. Panel, Front w/Components − CC/CV Models

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 121)

1 215 158 PLATE SCREENED, ident control; when ordering this item,. . . . . . . . . . . . . . . . . .

the nameplate should also be ordered) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 NAMEPLATE, screened (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 215 014 PANEL, engine/weld control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ♦220544 PANEL, engine/weld control ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S3 208278 SWITCH, range/changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R1 193 118 POT, cp flat 1t 2w 1k ohm linear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 S6 193 234 SWITCH, rotary 6 position gold contacts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197 527 GUARD, circuit breaker (For S6 − Not Included w/Harness) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 S5 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr 1. . . . . . . . . . . . . . . . . . . . . . . . . .

8 202 209 SPACER, nylon 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PC6 192 995 CIRCUIT CARD ASSY, connector/receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CB5 139 266 SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac frict 1. . . . . . . . . . . . . . . . .

11 CB6 083 432 SUPPLEMENTARY PROTECTOR, Man Reset 1p 10a 250vac Frict 1. . . . . . . . . . . . . . . .

803 650

Quantity

OM-4429 Page 78

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)

12 S2 021 467 SWITCH, tgl spst 3a 250v off−none−(on) spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 S1 212 436 SWITCH, ignition 4posn w/o handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CB1 201 083 SUPPLEMENTARY PROTECTOR, man reset 2P 20 A, 250VAC 1. . . . . . . . . . . . . . . . . .

201 553 CLIP, circuit breaker retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CB2 093 996 SUPPLEMENTARY PROTECTOR, man reset 1P 20A 250VAC frict 1. . . . . . . . . . . . . . . .

15 CB3 139 266 SUPPLEMENTARY PROTECTOR, man reset. . . . . . . . . . . .

1P 15A 250VAC (export models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 GFCI1 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

17 RC1 147 632 RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 RC1 176 355 RECEPTACLE, str 2p3w 16a 220v flange mtg (export models only) 1. . . . . . . . . . . . . .

18 RC5 ♦182 954 RCPT, str 3P4W 50A 125/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 ♦025 248 STAND-OFF, insul .250-20 x 1.2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 ♦604 102 CONNECTOR, clamp cable 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 ♦197 527 GUARD, circuit breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 ♦197 363 TERMINAL, ring tng screw clamp 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 CB7 ♦214 926 SUPPLEMENTARY PROTECTOR, man reset 3p 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 +215 347 PANEL, generator power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 +215 403 PANEL, gen pwr (export models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 ♦215 406 PANEL, generator power ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 +♦215 363 PANEL, generator power (full kVA option) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 ♦214 927 BOOT, circuit breaker 1 pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 ♦197 508 PLUG, protective 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 ♦077 440 BUSHING, conduit 1 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 601 836 NUT, 250−20 .50hex .19h brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 209 056 COVER, receptacle w/gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 083 030 STUD, brs .250−20 x 1.750 w/hex collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CT2 ♦

197 433 TRANSFORMER, current sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 190 861 LABEL, warning electric shock and moving parts etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 ♦197 399 LABEL, warning 3 ph generator power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 209 056 COVER, receptacle w/gasket 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 206 795 BOOT, circuit breaker clear hex nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 S12 ♦195 825 SWITCH, polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S12 ♦220 491 SWITCH, polarity/AC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 201 125 PANEL, mtg terminal pwr output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 199 303 PANEL, mtg terminal pwr output ss 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 PC4, PC5 189 744 CIRCUIT CARD ASSEMBLY, filter hf 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 735 WASHER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 134 201 STAND-OFF, support 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 181 169 SPACER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 186 621 BOOT, generic output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 ♦059 773 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 ♦010 647 PIN, spring cs .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 ♦196 073 LABEL, do not switch while welding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 021 385 BOOT, toggle switch lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 190 323 BOOT, circuit breaker clear hex nut 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 170 391 CONN, circ ms protective cap size 20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 HM 210 424 METER, hour 12−24vdc (snap−in) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 FUEL 192 265 GAUGE, fuel elec switch w/o sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 ♦193 228 METER, Volt Dc 8− 18 Scale 2.250 In Black Face 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 ♦217 084 GAUGE, Coolant Temp 0− 300 Deg F Electric 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197 798 SENDER, Coolant Temp 300 Deg F M16 X 1.5 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 217 083 GAUGE, Pressure Oil 0−100 Psi Electric 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 230 SENDER, Pressure Oil 0− 100 Psi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 ♦164 873 METER, amp ac/dc 0− 500 0−600 dc scale 2.5 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 ♦164 874 METER, volt ac/dc 0− 100 scale 2.5 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-4429 Page 79

55 097 922 KNOB, pointer .875 dia x .250 ID w/set screws plstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 189 161 HANDLE, switch range 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 010 647 PIN, spring CS .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 097 924 KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

024 103 BLANK, snap-in nyl .750 mtg hole blk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 304 BLANK, snap−in nyl .250 mtg hole black 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional

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

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

 Hardware is common and

not available unless listed.

5

3

4

2

1

35

36

37

20

11

12

28

27

10

26

9

8

7

6

29

30

31

32

33

34

13

14

25

16

15

17

18

21

22

19

23

24

804 291-A

Figure 13-6. Generator

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 13-6. Generator (Figure 13-1 Item 88)

1 132 053 SCREW, .375−16x1.50 hex hd−pln gr5 pld 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 183 387 WASHER, conical spring .406 ID x .875 OD pltd 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 195 911 ENDBELL, gen (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 143 220 O-RING, 2.859 ID x .139CS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 201 099 STATOR, exciter/gen pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 +208 287 STATOR, weld assembly complete 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6+♦209 220 STATOR, weld assembly complete (full kVA option) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 225 120 LABEL, warning moving parts can cause injury 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 190 197 GUARD, generator wire mesh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 172 674 SPRING, ext .240 OD x .041 wire x 3.500pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 039 207 BAFFLE, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 ROTOR 212 997 ROTOR, Generator Segmented Assy (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4429 Page 80

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 13-6. Generator (Continued)

12 210 446 ROTOR, Generator (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 024 617 RING, Rtng Ext 1.375 Shaft X .050 Thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 053 390 BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X .6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HUB, Drive (Not Sold Separately) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210 447 FAN, Rotor Assy Generator (Segmented) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 210 332 PLATE, Flex Hubmount 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 206 242 FAN, Rotor Segmented Assy Gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 049 026 SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 080 389 SCREW, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 197 487 FLYWHEEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 221 916 SENSOR, Speed (Magnetic) 5/8−18 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 197 486 ADAPTER, Engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 049 026 SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 191 579 COVER, starter hole /Continental 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

195 560 GUARD, starter hole deutz 912 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 083 883 WASHER, Lock .402idx0.709odx.087t Stl Split10mm 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 172 555 SCREW, M10-1.5 x 50hexhd pln 8.8pld 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 602 159 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 601 961 SCREW, .312-18 x 2.25hexhd pln gr 5pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 602 211 WASHER, lock .318 ID x 0.586 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 139 341 WASHER, exciter 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 *190 823 BRUSH, contact 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 208 469 CLIP, spring 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 189 142 BRUSHHOLDER ASSEMBLY, gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 602 242 WASHER, flat .375IDx0.875odx.083t stl pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 602 211 WASHER, Lock .318idx0.586odx.078t Stl Pld Split.312 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 604 534 SCREW, .312−18x1.25 hex hd−pln gr5 pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.

♦Optional

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

OM-4429 Page 81

 Hardware is common and

not available unless listed.

1

4

3

2

5

6

7

8

9

802 279-A

Figure 13-7. Main Rectifier Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 13-7. Main Rectifier Assembly (Figure 13-1 Item 114)

SR3 215 910 RECTIFIER, environmental (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 188 137 CONNECTION BOARD, rectifier AC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 188 517 BUS BAR, connection board 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 188 135 ENCLOSURE, rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 134 201 STAND-OFF, support 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PC3 215 755 CIRCUIT CARD ASSEMBLY, protection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 188 136 INSULATOR, heat sink 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 188 493 HEAT SINK, rectifier al 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 D3, D5, D7 208 334 DIODE, rect 275A 300V SP 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 D2, D4, D6 208 335 DIODE, rect 275A 300V RP 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OM-4429 Page 82

 Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components sepa-

rately or as part of the associated wiring harness.

Item

No.

Dia.

Mkgs.

D10/C10 189701 Diode/Capacitor Board, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB10 190374 Circuit Breaker, Auto Reset 12vdc 40 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR1 090104 Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR8 197325 Relay, Encl 12vdc Spst 70a 4pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC6 148439 Conn, Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . .

Part

No.

Description

Quantity

Wiring Harnesses

221374 Harness, Engine (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

156734 Nut, 010−32 .31hex .13h Stl Pld Sem Cone Wshr.38d 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

219886 Harness, Governor Control 404.22t 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218798 Conn, Deutsch Dtm 12p 2row Plug ’a’ 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218800 Conn, Deutsch Dtm Wedge Lock 12 Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

212117 Conn, Deutsch Wedge Lock 2 Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204702 Core, Toroidal .187 Id X .375 Od X .125 Thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218799 Conn, Deutsch Dtm 12p 2row Plug ’b’ 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218800 Conn, Deutsch Dtm Wedge Lock 12 Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

204702 Core, Toroidal .187 Id X .375 Od X .125 Thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192558 Harness, Range Switch (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190259 Harness, Wrg, Brushholder (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 168071 Conn, Rect Univ 084 9p/S 3row Plug Cable Lkg (Service Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

187651 Seal, Wire Univ 9p/S 3row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215013 Harness, Unit Weld Control CC (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 158465 Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187654 Seal, Wire Univ 12p/S 3row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 114063 Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215054 Harness, Control Box CC (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

D1/C1 189701 Diode/Capacitor Board, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC4 047483 Conn, Rect Univ 084 15p/S 3row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB11, 12, 13 139266 Supplementary Protector,Man Reset 1p 15a 250vac 3. . . . . . . . . . . . . . . . . . . . . . . .

CR7 188636 Relay, Ocv Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

S6 011622 Switch, Tgl 3pdt 15a 125vac On−none−on Spd Term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S5 011609 Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

150316 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

092670 Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC3 158466 Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC1 135133 Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4429 Page 83

215207 Harness, Unit Weld Control CV (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 114063 Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

PLG3 158465 Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187654 Seal, Wire Univ 12p/S 3row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196602 Plug, Cavity 18,30 Position Cinch Connector 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215377 Harness, Control Box, CC/CV (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB11, 12, 13 139266 Supplementary Protector,Man Reset 1p 15a 250vac 3. . . . . . . . . . . . . . . . . . . . . . . . . .

SR1 035704 Rectifier, Integ Bridge 40. Amp 800v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

RC4 047483 Conn, Rect Univ 084 15p/S 3row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC3 158466 Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC1 135133 Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

S6 193234 Switch, Rotary 6 Posn Gold Contacts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

S5 011609 Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D1/C1 189701 Diode/Capacitor Board, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

196602 Plug, Cavity 18,30 Position Cinch Connector 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196603 Seal, Switch 6 Position Rotary .250 Shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141450 Conn, Rect Metrmate 10skt 1row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

093995 Circuit Breaker, Man Reset 1p 15a 250vac Frict 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

201109 Harness, Receptacle Auxiliary Power (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC1 147632 Rcpt, Tw Lk Grd 2p3w 30a 250v *L6−30r 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GFCI1 151981 Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB2 093996 Supplementary Protector, Man Reset 1p 20a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

201053 Harness, Receptacle Auxiliary Power Export (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GFCI1 151981 Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB3 139266 Supplementary Protector, Man Reset 1p 15a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB2 093996 Supplementary Protector, Man Reset 1p 20a 250vac 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4429 Page 84

Warranty Questions?

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

Your distributor also gives
you ...

Service

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

Support

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

Effective January 1, 2007

(Equipment with a serial number preface of “LH” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the
engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches and Subarc (SAW) Guns

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

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

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

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

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.

miller_warr 2007−01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01