Miller Electric DU-OP User Manual

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Page 1

OM-494 191 862Q

September 2005

Processes

Stick (SMAW) Welding

MIG (GMAW) Welding Flux Cored (FCAW) Welding

TIG (GTAW) Welding

Air Carbon Arc (CAC-A) Cutting and Gouging

Description

Dual-Operator Engine Driven Welding Generator

Miller DU-OP

™

Visit our website at

www.MillerWelds.com

File: Engine Drive

Page 2

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

Page 3

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2-6. Proposition californienne 65 Avertissements 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

3-1. Symbols And Definitions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Description 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Weld, Power, And Engine Specifications 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Dimensions, Weights, And Operating Angles 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Fuel Consumption 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. AC Generator Power 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Duty Cycle And Overheating 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Volt-Ampere Curves 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Activating The Dry Charge Battery (If Applicable) 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Connecting The Battery 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Installing Exhaust Pipe 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Engine Prestart Checks 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Safety Information For Connecting To Weld Output Terminals 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Weld Output Terminals 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables 18 . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable 19 . . . . . . . . . . . . . . . . . . .

5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables 20 . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable 21 . . . . . . . . . . . . . . . . . . . . . . . . .

5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables 22 . . . . . . . . . . . . . . . .

5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable 23 . . . . . . . . . . . . . . . . .

5-14. Making Single Operator CC Weld Connections 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15. Selecting Weld Cable Sizes* 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-16. Installing Ether Cylinder (Optional Ether Starting Aid) 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-17. Remote 14 Receptacle Information 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-18. Remote 14 Receptacle Connections 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING THE WELDING GENERATOR 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Engine Controls 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Weld Controls (See Section 6-3) 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Weld Control Descriptions (See Section 6-2) 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 4

TABLE OF CONTENTS

SECTION 7 − OPERATING AUXILIARY EQUIPMENT 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. 120 Volt And 240 Volt Duplex Receptacles 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − MAINTENANCE & TROUBLESHOOTING 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Routine Maintenance 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Maintenance Label 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Servicing Air Cleaner 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Servicing Fuel And Lubrication Systems 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Adjusting Engine Speed 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Servicing Optional Ether Starting Aid 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Checking And Replacing Alternator Belt 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8. Resetting Fan Belt Safety Shutdown 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9. Inspecting And Cleaning Optional Spark Arrestor Muffler 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10. Checking Generator Brushes 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-11. Circuit Protection 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-12. Troubleshooting 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − ELECTRICAL DIAGRAMS 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − RUN-IN PROCEDURE 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Wetstacking 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Run-In Procedure Using Load Bank 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Run-In Procedure Using Resistance Grid 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − GENERATOR POWER GUIDELINES 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − PARTS LIST 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 5

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

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

1-1. Symbol Usage

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

rom _nd_3/05

 Marks a special safety message.

 Means “Note”; not safety related.

1-2. Arc Welding Hazards

 The symbols shown below are used throughout this manual to

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

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

pair this unit.

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

ELECTRIC SHOCK can kill.

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

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

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

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

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

danger of falling.

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

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

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

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

1910.147 (see Safety Standards).

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

and national, state, and local codes.

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

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

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

double-check connections.

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

cord immediately if damaged — bare wiring can kill.

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

arate cable.

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

er electrode from a different machine.

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

once. Maintain unit according to manual.

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

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

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

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

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

table as near the weld as practical.

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

with any metal object.

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

output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine.

 Stop engine on inverter and discharge input capacitors according to

instructions in Maintenance Section before touching any parts.

FUMES AND GASES can be hazardous.

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

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

remove welding fumes and gases.

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

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

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

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

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

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

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

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

BUILDUP OF GAS can injure or kill.

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

air-supplied respirator.

ARC RAYS can burn eyes and skin.

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

 Wear an approved welding helmet fitted with a proper shade of filter lenses

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

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

sparks; warn others not to watch the arc.

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

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

OM-494 Page 1

Page 6

WELDING can cause fire or explosion.

HOT PARTS can cause severe burns.

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

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

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

possible, tightly cover them with approved covers.

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

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

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

through small cracks and openings to adjacent areas.

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

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

fire on the hidden side.

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

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

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

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

 Do not use welder to thaw frozen pipes.

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

when not in use.

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

fless trousers, high shoes, and a cap.

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

person before doing any welding.

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

work and have a fire watcher and extinguisher nearby.

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

FLYING METAL can injure eyes.

 Welding, chipping, wire brushing, and grinding cause

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

 Wear approved safety glasses with side shields even

under your welding helmet.

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

heavy, insulated welding gloves and clothing to prevent burns.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

 Wear approved ear protection if noise level is high.

MAGNETIC FIELDS can affect pacemakers.

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

near arc welding, gouging, or spot welding operations.

CYLINDERS can explode if damaged.

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

 Protect compressed gas cylinders from excessive heat, mechanical

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

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

cylinder rack to prevent falling or tipping.

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

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

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

connected for use.

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

sons to llift and move cylinders.

 Read and follow instructions on compressed gas cylinders, associated

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

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

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

tive clothing when working on a battery.

 Stop engine before disconnecting or connecting bat-

tery cables or servicing battery.

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

FUEL can cause fire or explosion.

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

ing fuel.

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

sparks or open flames.

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

OM-494 Page 2

MOVING PARTS can cause injury.

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

and securely in place.

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

maintenance and troubleshooting as necessary.

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

battery cable from battery.

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

before starting engine.

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

engine from kicking back or starting.

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

nents.

HOT PARTS can cause severe burns.

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

a hot engine.

Page 7

STEAM AND HOT COOLANT can burn.

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

avoid scalding.

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

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

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

follow the next two statements.

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

moving cap.

BATTERY ACID can BURN SKIN and EYES.

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

ENGINE HEAT can cause fire.

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

surfaces or flammables.

 Keep exhaust and exhaust pipes way from flam-

mables.

ENGINE EXHAUST GASES can kill.

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

eas.

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

and away from any building air intakes.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can cause serious injury or death.

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

COMPRESSED AIR can cause injury.

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

TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury.

 Release air pressure from tools and system before

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

EXHAUST SPARKS can cause fire.

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

quired areas — see applicable codes.

HOT METAL from air arc cutting and gouging can cause fire or explosion.

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

HOT PARTS can cause burns and injury.

 Do not touch hot compressor or air system parts.  Let system cool down before touching or servicing.

READ INSTRUCTIONS.

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

servicing.

 Use only genuine Miller/Hobart replacement parts.

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

FALLING UNIT can cause injury.

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

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

 Lift and support unit only with proper equipment and

correct procedures.

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

enough to extend beyond opposite side of unit.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or stop-

ping engine.

 Do not let low voltage and frequency caused by low

engine speed damage electric motors.

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

applicable.

FLYING SPARKS can cause injury.

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

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

 Sparks can cause fires — keep flammables away.

OVERUSE can cause OVERHEATING.

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

to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

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

move, or ship PC boards.

TILTING OF TRAILER can cause injury.

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

ing to instructions supplied with trailer.

OM-494 Page 3

Page 8

READ INSTRUCTIONS.

ARC WELDING can cause interference.

 Use only genuine MILLER/Hobart replacement

parts.

 Perform engine and air compressor (if applicable)

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

H.F. RADIATION can cause interference.

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

tion, safety services, computers, and communications equipment.

 Have only qualified persons familiar with electronic

equipment perform this installation.

 The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the installation.

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

once.

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

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

1-6. California Proposition 65 Warnings

 Welding or cutting equipment produces fumes or gases which

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

 Battery posts, terminals and related accessories contain lead

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

 Electromagnetic energy can interfere with sensitive

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

 Be sure all equipment in the welding area is electro-

magnetically compatible.

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

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

 Locate welding operation 100 meters from any sensitive electronic

equipment.

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

manual.

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

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

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

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

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

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

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

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

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

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone: 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, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website: www.cganet.com).

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

1-8. EMF Information

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

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

OM-494 Page 4

levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or in Toronto 416-747-4044, website: www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 10036–8002 (phone: 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, 1 Battery March Park, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org.

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

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

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

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

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

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

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

About Pacemakers:

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

Page 9

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

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

2-1. Signification des symboles

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

 Identifie un message de sécurité particulier.

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

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

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

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

rom_fre 3/05

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

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

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

confiés qu’à des personnes qualifiées.

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

lièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

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

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

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

trous.

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

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

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

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

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

procédé de soudage le demande.

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

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

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

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

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

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

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

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

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

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

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

à la terre approprié et contre-vérifier les connexions.

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

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

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

mal épissés.

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

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

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

une électrode provenant d’une autre machine.

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

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

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

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

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

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

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

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

tout objet métallique.

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

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

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

LES FUMÉES ET LES GAZ peuvent être dangereux.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

teur d’adduction d’air homologué.

sation.

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

Le rayonnement de l’arc du procédé de soudage génère des

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

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

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

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

que.

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

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

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

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

rayons visibles et invisibles intenses (ultraviolets et infrarou-

OM-494 Page 5

Page 10

LE SOUDAGE peut provoquer un incendie ou une explosion.

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

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

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

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

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

substances inflammables.

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

chaud.

 Des étincelles et des matériaux chauds du soudage peuvent facilement

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

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

clencher un incendie de l’autre côté.

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

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

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

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

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

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

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

ou couper le fil à la pointe de contact.

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

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

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

qu’un allumeur au butane ou des allumettes.

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

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

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

DES PARTICULES VOLANTES peuvent blesser les yeux.

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

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

froidissement des soudures, elles risquent de projeter du laitier.

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

particules métalliques volantes. Pendant la période de re-

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

exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

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

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

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

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

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

ques.

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

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

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

de branchement de la bouteille.

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

personnes pour soulever et déplacer les bouteilles.

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

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

2-3. Dangers existant en relation avec le moteur

L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE.

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

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

 Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.  Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie.  Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicu-

les de démarrage rapide.

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

LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.

 Arrêter le moteur avant de vérifier le niveau de carburant

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

flamme nue.

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

expansion.

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

renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.

ou de faire le plein.

DES ORGANES MOBILES peuvent provoquer des blessures.

 Ne pas approcher les mains des ventilateurs, courroies et

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

ments et dispositifs de protection.

OM-494 Page 6

autres pièces en mouvement.

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

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

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

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

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

mobiles.

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

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

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

route accidentelle du moteur.

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

générateur.

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

moteur chaud.

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

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

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

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

l’équipement.

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

LE BRUIT peut affecter l’ouïe.

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

 Porter des protections approuvés pour les oreilles si le ni-

veau sonore est trop élevé.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

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

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

Si des BOUTEILLES sont endommagées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut

DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.

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

maintenance.

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

 Il est préférable de vérifier le liquide de refroidissement

une fois le moteur refroidi pour éviter de se brûler.

Page 11

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

du radiateur.

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

ver le bouchon.

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

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

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

rateur d’adduction d’air homologué.

utilisation.

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

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

2-4. Dangers liés à l’air comprimé

LA CHALEUR DU MOTEUR peut pro- voquer un incendie.

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

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

surfaces inflammables.

LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du moteur de

provoquer un incendie.

 Utiliser uniquement un pare-étincelles approuvé − voir

codes en vigueur.

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

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

geage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer des blessures.

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

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

nance.

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

 Ne pas couper ou gouger à proximité de produits in-

flammables.

 Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.

 Ne pas toucher le compresseur ou d’autres éléments

du circuit air comprimé chauds.

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

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

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

 Utiliser uniquement des pièces de rechange Miller/Hobart.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation ou la

maintenance de l’appareil.

 Arrêter le moteur et relâcher la pression avant d’ef-

fectuer la maintenance.

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

LA CHUTE DE L’APPAREIL peut blesser.

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

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

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

approprié et en suivant les procédures adéquates.

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

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

LE SURCHAUFFEMENT peut endommager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant de démarrer ou

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

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

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

lieu.

d’arrêter le moteur.

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

ou expédier des cartes de circuits imprimes.

L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter le facteur de

marche nominal.

 Réduire le courant ou le facteur de marche avant de

poursuivre le soudage.

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

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

 Établir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pièces.

LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.

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

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

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

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

flammable.

UNE REMORQUE QUI BASCULE peut entraîner des blessures.

 Utiliser les supports de la remorque ou des blocs pour

soutenir le poids.

 Installer convenablement le poste sur la remorque com-

me indiqué dans le manuel s’y rapportant.

OM-494 Page 7

Page 12

LIRE LES INSTRUCTIONS.

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

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

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

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

des interférences avec les équipements de radio−navigation et de communication, les services de

 Demander seulement à des personnes qualifiées familiarisées avec des

équipements électroniques de faire fonctionner l’installation.

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

fié les interférences résultant de l’installation.

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

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

sécurité et les ordinateurs.

2-6. Proposition californienne 65 Avertissements

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

 L’énergie électromagnétique risque de provoquer des in-

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

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

électromagnétiquement.

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

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

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

tronique sensible.

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

ment à ce mode d’emploi.

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

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

nateur tel que les robots.

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

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

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

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

2-7. Principales normes de sécurité

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

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

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

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

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

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

2-8. Information EMF

Pour les moteurs à essence :

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

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

Pour les moteurs diesel :

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

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

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

Practice For Occupational And Educational Eye And Face Protection,

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

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

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

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

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

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

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

OM-494 Page 8

procédures suivantes :

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

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

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

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

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

En ce qui concerne les stimulateurs cardiaques

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

Page 13

SECTION 3 − DEFINITIONS

3-1. Symbols And Definitions

Stop Engine Start Engine Ether Starting Aid Engine

Do Not Switch While Welding

Or Under Load

Battery (Engine) Circuit Breaker Engine Oil

Check Injectors/

Pump

Positive Negative

Amperes

Check Valve

Clearance

Certified/Trained

Volts Panel/Local Remote

On Temperature Output (Contactor)

Stick (SMAW)

Welding

Time

TIG (GTAW)

Welding

Hours

Read Operator’s

Manual

MIG (GMAW)

Fuel

Mechanic

Welding

Seconds

Protective Earth

(Ground)

Welding Arc

Alternating

Current

Three Phase

Single Phase

OM-494 Page 9

Page 14

SECTION 4 − SPECIFICATIONS

120/240 V AC

Air Cooled,

22.3 gal Dual

Volts DC, 40%

(/ y

Engine

Engine End

 Do not exceed tilt angles or engine could

tip.

angles_1 8/99

158 699

4-1. Description

This unit has two CC/CV modules with separate weld controls for applications where two welding arcs are needed. A Welder Selector switch controls whether one or both sets of weld output terminals are active (see Section 6-2). When the unit is operated in the dual operator mode, each welder has CC and CV weld output available for Stick, TIG, and MIG welding. When in the single operator mode, CC weld output is available to the welder on the Welder B (right) side only (CV not active in single operator mode).

4-2. Weld, Power, And Engine Specifications

Max.

Open-

Circuit

Voltage

Rated

Welding

Output

550 A at 30

Volts DC, 40%

Duty Cycle

275 A at 31

Volts DC, 40%

Duty Cycle

Weld

Mode

Single

Dual

Weld

Stations

Available

(Right Side)

(Both Sides)

Weld

Output

CC/DC 30 − 600 A 85

CC/DC 15 − 300 A 85

CV/DC 10 − 32 V 49

Weld

Output

Range

4-3. Dimensions, Weights, And Operating Angles

Dimensions

Height 47-5/8 in (1210 mm)

Width 31-1/4 in (794 mm) Depth 60-1/2 in (1537 mm)

A 59-1/8 in (1502 mm) B 47-1/4 in (1200 mm) C 43-1/4 in (1099 mm) D 32-3/4 in (832 mm) E 24-15/16 in (633 mm) F 10-1/2 in (267 mm) G 6-1/2 in (165 mm) H 2-7/8 in (73 mm)

J 29-7/8 in (759 mm)

K 11/16 in (24 mm)

21/32 in (17 mm) Dia.

16 Holes

Weight

2005 lb (909 kg)

Lifting Eye Weight Rating:

2161 lb (980 kg) Maximum

158 699

Generator Power

Single-Phase,

4 kVA/kW, 34/17 A,

120/240 V AC,

(4 kVA/kW Shared By

All Receptacles)

 Do not exceed tilt angles or engine could

 Do not move or operate unit where it could

Rating

50/60 Hz

be damaged or unit could tip.

tip.

20° 20°

Engine

Deutz F3L-912

Air-Cooled,

Three-Cylinder,

41.5 HP Diesel Engine

Fuel

Capacity

(84.4 L)

17.5°

angles_1 8/99

OM-494 Page 10

Page 15

4-4. Fuel Consumption

The curve shows typical fuel use under the combined weld loads of both sides (Welder A and Welder B).

7.57

6.62

5.67

4.73

3.78

2.84

1.98

0.95

LITERS/HR.

1.70

1.46

1.25

1.04

0.83

0.62

0.40

0.21

IMP. GAL./HR.

2.00

1.75

1.50

1.25

1.00

0.75

0.50

0.25

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

U.S. GAL./HR.

DC WELD AMPERES AT 40% DUTY CYCLE

4-5. AC Generator Power

300

150

250

125

200

100

150

AC VOLTS

100

0 5 10 15 20 25 30

AC AMPERES IN 240V MODE

195 711

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

0102030405060

AC AMPERES IN 120V MODE

193 018

OM-494 Page 11

Page 16

4-6. Duty Cycle And Overheating

Dual Operator Mode − 40% Duty Cycle At 275 Amperes From Each Side Single Operator Mode − 40% Duty Cycle At 550 Amperes From Welder B side (Right)

4 Minutes Welding 6 Minutes Resting

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

 Exceeding duty cycle can

damage unit and void warranty.

If a weld module overheats, the High Temperature light goes on and the thermostat opens to stop weld output to that module. Wait fifteen minutes for module to cool. Reduce amperage, voltage, or duty cycle before welding.

This unit has separate duty cycle ratings for each operating mode. If the unit is operated in the dual operator mode, the unit is rated at 40% duty cycle. This means each side of the unit can be operated at 275 amperes at 40% duty cycle.

When the unit is operated in the single operator mode, the Welder B side (right) is rated at 40% duty cycle (550 A at 40% duty cycle).

Overheating

Minutes

A or V

Reduce Duty Cycle

Ref. rduty1 5/95 − 194 313-A

OM-494 Page 12

Page 17

4-7. Volt-Ampere Curves

A. CC/DC − Single Mode

100

DC VOLTS

MIN MED MAX

0 100 200 300 400 500 600 700 800 900 1000

B. CC/DC − Dual Mode

100

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

DC AMPERES

DC VOLTS

0 50 100 150 200 250 300 350 400 450 500

C. CV/DC Mode

100

DC VOLTS

MAX MED

MIN

MAXMEDMIN

DC AMPERES

0 100 200 300 400 500 600 700 800 900 1000

DC AMPERES

194 397 / 194 398 / 194 399

OM-494 Page 13

Page 18

SECTION 5 − INSTALLATION

NOTE

When facing the front panel, the Welder B controls and weld terminals are on the right and the Welder A controls and weld terminals are on the left.

5-1. Installing Welding Generator

Movement Airflow Clearance Location

18 in

(460 mm)

install1 11/02* − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

18 in

(460 mm)

18 in

 Always securely fasten welding

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

 Always ground generator frame

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

 If unit does not have GFCI recep-

tacles, use GFCI-protected extension cord.

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.

 Be sure equipment connected to

the 240 V receptacles is GFCI-

protected.

 Do Not Lift Unit From End

18 in

(460 mm)

18 in

(460 mm)

Grounding

GND/PE

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

 Bed liners, shipping skids, and some running

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

Notes

OM-494 Page 14

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at the beginning of this manual.

Page 19

5-2. Activating The Dry Charge Battery (If Applicable)

 Always wear a face shield,

rubber gloves and protective clothing when working on a battery.

Remove battery from unit. 4 Vent Caps 5 Sulfuric Acid Electrolyte

(1.265 Specific Gravity) 6 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.

7 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

5-3. Connecting The Battery

 Connect (−) Cable Last.

−

drybatt1 6/05 − S-0886

−

190 377

OM-494 Page 15

Page 20

5-4. Installing Exhaust Pipe

Tools Needed:

1/2 in

5-5. Engine Prestart Checks

1/2 in

(13 mm)

Diesel

Valve Open

Full

 Stop engine and let cool.  Do not blow exhaust toward

air cleaner or air intake.

Top View

exh_pipe2 4/96 − 154 089-A / 154 611 / 190 377

Check all fluids daily. Engine must be cold and on a level surface.

Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe during run-in, see Section 10.

Fuel  Do not use gasoline. Gaso-

line will damage engine.

Add diesel fuel before starting engine the first time (see maintenance label for specifications). Fill fuel tank up to 1/2 in. (13 mm) from top to allow room for expansion. Open fuel shut-off valve.

Do not run out of fuel or air enters fuel system and causes 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).

 Engine stops if oil pressure is

too low.

 To improve cold weather

starting:

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

OM-494 Page 16

Full

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.

Ref. 158 633-C / S-176 697

Page 21

5-6. Safety Information For Connecting To Weld Output Terminals

 UNEXPECTED WELD OUTPUT can cause injury or fire.

 Both weld outputs can be live (ON) when Welder Selector switch is in Welder A/Welder B position and engine is running.  Disconnect or insulate any unused cables.  Know where cables are located BEFORE starting engine.

 ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical connections.

 Stop engine before making any weld output connections.  Do not connect welding output of different polarities to the same structure.  See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual).  When welding on the same workpiece, all connections to the workpiece must be of the same polarity.  Do not handle or come in contact with two live electrodes at the same time.

 ELECTRIC SHOCK can kill; TWO TIMES NORMAL OPEN-CIRCUIT VOLTS can exist between electrode holders of opposite polarity.

 Do not touch electrode holders of opposite polarity at the same time.  Separate electrode holders of opposite polarity to prevent contact.  Consult ANSI Z49.1 for common grounding safe practices.

5-7. Weld Output Terminals

Welder A (Left) Side

 Dinse receptacles only on units

with Polarity switch option.

Welder B (Right) Side

123

 Stop engine.

1 Negative (−) Weld Output Terminal

2 CV Weld Output Terminal

3 CC Weld Output Terminal

4 Dinse Weld Receptacles (Only On

Units With Polarity Switch Option)

See Sections 5-8 thru 5-13 for dual operator output connections for CC and CV welding.

See Section 5-14 for single operator output

Tools Needed:

3/4 in

Ref. 190 377 / 802 292-A / 802 554

connections (CC only). If unit has the Polarity switch option, the

Negative (−) weld output terminals are labeled Work receptacles and the CC weld output terminals are labeled Electrode receptacles.

OM-494 Page 17

Page 22

5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables

Tools Needed:

Direct Current Electrode Positive (DCEP) connections are shown.

3/4 in

Welder A (Left) Side

Note position

of Process

Selector

switches.

Welder B (Right) Side

 Stop engine.  Do not exceed machine duty cycle.

 Use Dual Operator mode for CC and

CV welding (see Section 6-1).

See Section 5-15 for proper cable size. 1 Strain Reliefs Route cables through strain reliefs.

OM-494 Page 18

2 Electrode Holder Cables 3 Work Cables For Stick/TIG welding Direct Current Elec-

trode Positive (DCEP), connect work cables to Negative (−) terminals and elec- trode holder cables to CC terminals.

For Stick/TIG Direct Current Electrode Negative (DCEN), connect work cables to

Ref. 190 377 / 802 292-A

CC terminals and electrode holder cables to Negative (−) terminals.

If unit has the Polarity switch option, connect work cables to Work receptacles and electrode holder cables to Electrode receptacles.

 Be sure Process Selector switches are

set correctly. See Section 6-3.

Page 23

5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable

Tools Needed:

 INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.

When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−) weld termi- nals, and connect a single weld cable of adequate size from the Welder B (right) Negative (−) terminal to the workpiece.

When using these connections as a common work terminal, all connections must be of the same polarity. For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see Section 5-15

for proper cable size).

Direct Current Electrode Positive (DCEP) connections are shown.

3/4 in

Welder A (Left) Side

Welder B (Right) Side

Note position

of Process

Selector

switches.

Ref. 190 377 / 802 292-A

 Stop engine.  Do not exceed machine duty cycle.

 For common work connection, work

cable must be able to carry combined weld output of both CC weld output terminals (see Section 5-15 for proper cable size).

 Use Dual Operator mode for CC and

CV welding (see Section 6-1).

1 Strain Relief Route cables through strain reliefs. 2 Electrode Holder Cables 3 Work Jumper Cable

4 Common Work Cable

For Stick/TIG welding Direct Current Electrode Positive (DCEP), connect common work cable and work jumper cable to Welder B (right) Negative (−) terminal. Connect other end of work jumper cable to Welder A (left) Negative (−) terminal.

Connect electrode holder cables to CC terminals.

For Stick/TIG Direct Current Electrode Negative (DCEN), connect common work cable and work jumper cable to Welder B (right) CC terminal. Connect other end of

work jumper cable to Welder A (left) CC terminal.

Connect electrode holder cables to Negative (−) terminals.

If unit has the Polarity switch option, connect common work cable and work jumper cable to Welder B (right) Work receptacle. Connect other end of work jumper cable to Welder A (left) Work receptacle.

Connect electrode holder cables to Electrode receptacles.

 Be sure Process Selector switches

and optional Polarity switches are set correctly. See Section 6-3.

OM-494 Page 19

Page 24

5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables

Tools Needed:

Direct Current Electrode Positive (DCEP) connections are shown.

3/4 in

Welder A (Left) Side

Note position

of Process

Selector

switches.

Note position

of optional

Polarity

switch.

Welder B (Right) Side

Note position

of optional Po-

larity switch.

 Stop engine.  Do not exceed machine duty cycle.

 Use Dual Operator mode for CC and

CV welding (see Section 6-1).

See Section 5-15 for proper cable size. 1 Strain Reliefs Route cables through strain reliefs. 2 Wire Feeder Cables

OM-494 Page 20

3 Work Cables

For MIG and FCAW welding Direct Current Electrode Positive (DCEP), connect work cables to Negative (−) terminals and wire feeder cables to CV terminals.

For MIG and FCAW Direct Current Electrode Negative (DCEN), connect work cables to CV terminals and wire feeder cables to Negative (−) terminals.

Ref. 190 377 / 802 292-A

If unit has the Polarity switch option, connect work cables to Work receptacles and wire feeder cables to CV receptacles.

 Place optional Polarity switches in Re-

verse position when using CV weld receptacles. There is no CV weld output when switch is in Straight position.

 Be sure Process Selector and Polarity

switches are set correctly. See Section 6-3.

Page 25

5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable

Tools Needed:

 INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.

for proper cable size).

3/4 in

Welder A (Left) Side

Note position

of optional

Polarity

switch.

Direct Current Electrode Positive (DCEP) connections are shown.

Note position

of Process

Selector

switches.

Welder B (Right) Side

Note position of optional

Polarity switch.

 Stop engine.  Do not exceed machine duty cycle.

 For common work connection, work

cable must be able to carry combined weld output of both CC weld output terminals (see Section 5-15 for proper cable size).

 Use Dual Operator mode for CC and

CV welding (see Section 6-1).

1 Strain Relief Route cables through strain reliefs. 2 Wire Feeder Cables 3 Work Jumper Cable

4 Common Work Cable

For MIG and FCAW welding Direct Current Electrode Positive (DCEP), connect common work cable and work jumper cable to Welder B (right) Negative (−) terminal. Connect other end of work jumper cable to Welder A (left) Negative (−) terminal.

Connect wire feeder cables to CV terminals.

For MIG and FCAW Direct Current Electrode Negative (DCEN), connect common work cable and work jumper cable to Welder B (right) CV terminal. Connect other end of work jumper cable to Welder A (left) CV terminal.

Ref. 190 377 / 802 292-A

Connect wire feeder cables to Negative (−) terminals.

If unit has the Polarity switch option, connect common work cable and work jumper cable to Welder B (right) Work receptacle. Connect other end of work jumper cable to Welder A (left) Work receptacle.

Connect wire feeder cables to CV receptacles.

 Place optional Polarity switches in Re-

verse position when using CV weld receptacles. There is no CV weld output when switch is in Straight position.

 Be sure Process Selector and Polarity

switches are set correctly. See Section 6-3.

OM-494 Page 21

Page 26

5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables

Tools Needed:

3/4 in

Direct Current Electrode Positive (DCEP) connections are shown.

Welder A (Left) Side

Note position

of Process

Selector

switches.

Welder B (Right) Side

Note position

of optional

 Stop engine.  Do not exceed machine duty cycle.

Polarity

switch.

 Use Dual Operator mode for CC and

CV welding (see Section 6-1).

See Section 5-15 for proper cable size. 1 Strain Reliefs Route cables through strain reliefs. 2 Electrode Holder Cable 3 Wire Feeder Cable 4 Work Cables For Stick/TIG welding Direct Current Elec-

trode Positive (DCEP), connect work cable

to Negative (−) terminal and electrode holder cable to CC terminal.

For Stick/TIG Direct Current Electrode Negative (DCEN), connect work cable to CC terminal and electrode holder cable to Negative (−) terminal.

 Be sure Process Selector switches are

set correctly. See Section 6-3.

For MIG and FCAW welding Direct Current Electrode Positive (DCEP), connect work cable to Negative (−) terminal and wire feeder cable to CV terminal.

For MIG and FCAW Direct Current Electrode Negative (DCEN), connect work cable to CV terminal and wire feeder cable to Negative (−) terminal.

Ref. 190 377 / 802 292-A

For Stick/TIG welding on units with Polarity switch option, connect work cable to Work receptacle and electrode cable to Electrode receptacle.

For MIG/FCAW welding on units with Polarity switch option, connect work cable to Work receptacle and wire feeder cable to CV receptacle.

 Place optional Polarity switches in Re-

verse position when using CV weld receptacles. There is no CV weld output when switch is in Straight position.

 Be sure Process Selector and Polarity

switches are set correctly. See Section 6-3.

OM-494 Page 22

Page 27

5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable

Tools Needed:

3/4 in

 INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.

for proper cable size).

Direct Current Electrode Positive

Welder A (Left) Side

(DCEP) connections are shown.

Note position

of Process

Selector

switches.

Welder B (Right) Side

Note position of optional Polarity

switch.

 Stop engine.  Do not exceed machine duty cycle.

 For common work connection, work

cable must be able to carry combined weld output of both CC weld output terminals (see Section 5-15 for proper cable size).

 Use Dual Operator mode for CC and CV

welding (see Section 6-1).

1 Strain Reliefs Route cables through strain reliefs. 2 Electrode Holder Cable 3 Wire Feeder Cable 4 Work Jumper Cable 5 Common Work Cable

For Direct Current Electrode Positive (DCEP), connect common work cable and work jumper cable to Welder B (right) Negative (−) terminal. Connect other end of work jumper cable to Welder A (left) Negative (−) terminal.

Connect electrode holder cable to either CC terminal.

Connect wire feeder cable to CV terminal on other side.

 Be sure Process Selector switches are

set correctly. See Section 6-3.

For Direct Current Electrode Negative (DCEN), connect common work cable and work jumper cable to Welder B (right) CC terminal. Connect other end of work jumper cable to Welder A (left) CV terminal.

Ref. 190 377 / 802 292-A

Connect electrode holder cable to either Negative (−) terminal, and wire feeder cable to remaining Negative (−) terminal.

If unit has the Polarity switch option, connect common work cable and work jumper cable to Welder B (right) Work receptacle. Connect other end of work jumper cable to Welder A (left) Work receptacle.

Connect electrode holder cable to either Electrode receptacle.

Connect wire feeder cable to CV receptacle on other side.

 Place optional Polarity switch in Re-

verse position when using CV weld receptacle. There is no CV weld output when switch is in Straight position.

 Be sure Process Selector and Polarity

switches are set correctly. See Section 6-3.

OM-494 Page 23

Page 28

5-14. Making Single Operator CC Weld Connections

Direct Current Electrode Positive (DCEP) connections are shown.

Welder A (left) Terminals Inactive

In Single Operator Mode

Note position

of Process

Selector

switch.

Welder B(Right) Side

Tools Needed:

3/4 in

 Stop engine.  Do not exceed machine duty cycle.

 Welder A (left) weld output terminals

are disabled in Single Operator mode. Connect only to Welder B (right) terminals for Single Operator mode operation.

 Use Single Operator mode for CC weld-

ing only. Welder A and Welder B CV weld output terminals are disabled in

OM-494 Page 24

Single Operator mode. (see Section 5-8).

 See Section 5-15 for proper cable size.

See Section 5-15 for proper cable size. 1 Strain Relief Route cables through strain reliefs. 2 Electrode Holder Cable 3 Work Cable For Stick/TIG welding Direct Current Elec-

trode Positive (DCEP), connect work cable

190 377 / 802 292-A

to Negative (−) terminal and electrode holder cable to CC terminal.

For Stick/TIG Direct Current Electrode Negative (DCEN), connect work cable to CC terminal and electrode holder cable to Negative (−) receptacle.

If unit has the Polarity switch option, connect work cable to Work terminal and electrode holder cable to Electrode receptacle.

 Be sure Process Selector switch is set

correctly. See Section 6-3.

Page 29

Notes

OM-494 Page 25

Page 30

5-15. Selecting Weld Cable Sizes*

100 ft (30 m) or Less

Weld Output

Terminals

 Turn off power 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)

600 3/0 (95) 4/0 (120)

700 4/0 (120)

800 4/0 (120)

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

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

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

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

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)

3 ea. 4/0

(3x120)

3 ea. 4/0

(3x120)

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)

3 ea. 4/0

(3x120)

3 ea. 4/0

(3x120)

4 ea. 4/0

(4x120)

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)

3 ea. 4/0

(3x120)

4 ea. 4/0

(4x120)

4 ea. 4/0

(4x120)

OM-494 Page 26

Page 31

5-16. Installing Ether Cylinder (Optional Ether Starting Aid)

 Stop engine.  Improper handling or expo-

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

 Do not use Ether Starting Aid

while engine is running.

Open right side door. 1 Ether Cylinder 2 Nozzle Remove cover and clean cylinder

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

Install cylinder on fitting. Tighten clamp.

 After installing cylinder, wait at

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

Put cap on fitting when cylinder is removed.

5-17. Remote 14 Receptacle Information

NOTE

24 VOLTS AC

REMOTE

OUTPUT

CONTROL

A/V

AMPERAGE

VOLTAGE

Place Welder Selector switch in Welder A/Welder B position (dual operator mode) for both remote receptacles to work. Welder A (left) remote receptacle output contactor and control is disabled when switch is in Welder B position.

Socket* Socket Information

A 24 volts ac. Protected by circuit breakers CB5 and CB6.

B Contact closure to A completes 24 volts ac contactor control circuit.

C Output to remote control; +10 volts dc in CV, 0 to +10 volts dc in CC.

D Remote control circuit common.

E 0 to +10 volts dc input command signal from remote control.

Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.

Voltage feedback; +1 volts dc per 10 arc volts.

ether1 7/96 − 153 382-A / 190 377 / 802 291-A

115 VOLTS AC

GND

*The remaining sockets are not used.

K Chassis common.

G Circuit common for 24 and 115 volts ac circuits.

115 volts, 15 amperes, 60 Hz ac. Protected by circuit breakers CB5 and CB6.

Contact closure to I completes 115 volts ac contactor control circuit.

OM-494 Page 27

Page 32

5-18. Remote 14 Receptacle Connections

Dual Operator Operation

Single Operator Operation

600 AMPS

OM-494 Page 28

Ref. 802 291-A

Page 33

SECTION 6 − OPERATING THE WELDING GENERATOR

NOTE

6-1. Engine Controls

When facing the front panel, the Welder B controls and weld terminals are on the right and the Welder A side controls and weld terminals are on the left.

451

 See Section 6-3 for weld control

descriptions.

1 Engine Start Button 2 Manual Stop Control 3 Ether Starting Aid Switch (Optional) Push switch up and release while cranking

engine to release ether.

To Start: Press button and use Ether switch (if necessary). Release button when engine starts.

 If the engine does not start, let engine

come to a complete stop before attempting restart.

190 377

To Stop: Pull control out and hold. Release control when engine stops.

4 Battery Charging Warning Light Light goes on when battery is not charging.

 If light goes on, stop engine and check

engine belt.

5 Engine Hour Meter

OM-494 Page 29

Page 34

6-2. Weld Controls (See Section 6-3)

300 AMPS 300 AMPS

WELDER A Welder B

600 AMPS

Welder B

600 AMPS

342

897

OM-494 Page 30

Ref. 191 848

Page 35

6-3. Weld Control Descriptions (See Section 6-2)

1 Welder Selector Switch Use switch to select Dual Operator or Single

Operator welding mode. Place switch in Welder A/Welder B (dual oper-

ator) position for CC and CV output from Welder A (left) and Welder B (right) weld output terminals. Control the weld output from the terminals on each side using the weld controls on that same side.

Place switch in Welder B (single operator) position for CC weld output from Welder B (right) weld output terminals only. CV weld output terminals on both sides do not work when unit is in Single Operator mode.

 Welder A (left) weld output terminals are

disabled in Single Operator mode. Connect only to Welder B (right) terminals for Single Operator operation.

 When in single Operator mode, only CC

weld output is available. Welder A (left) and Welder B (right) side CV weld output terminals are disabled in Single Operator mode. (see Section 5-8).

2 Process Selector Switch Use switch to select output for weld process.

If switch is in Stick/Tig position, place Welder Selector switch in Welder A/Welder B or Welder B Position. If switch is in MIG position, place Welder Selector switch in Welder A/Welder B position only.

 CV weld output for MIG is only available

when Welder Selector switch is in Welder A/Welder B position. All weld output

stops if either Process Selector switch is placed in MIG position when Welder Selector switch is in Welder B position.

 Place optional Polarity switch in Reverse

position when using CV weld output. There is no CV weld output when Polarity switch is in Straight position.

 Do not switch under load or with out-

put on.

3 Arc Force (Dig) Control Use control to automatically increase amper-

age as arc length is decreased to assist in arc starts and reduce the chance of the electrode sticking in the puddle. Turn clockwise to increase short-circuit amperage. Set at minimum for TIG welding.

4 Hot Start Switch Use switch to disable hot start circuit. Turn

switch On for Stick (SMAW) and Submerged Arc (SAW) Welding, and Air Carbon Arc Cutting and Gouging (CAC-A). Turn switch Off for TIG (GTAW) welding.

When switch is in On position, higher short-circuit amperage helps arc starting. After arc starts, the front panel or remote Amperage/ Voltage control setting determines weld amperage.

 The hot start circuit does not function

when constant voltage (CV) welding.

5 Amperage/Voltage Control

When Process Selector switch is in the Stick/ TIG position, turn control clockwise to increase amperage. Read amperage from outer scale of control. The Amperage/Voltage control adjusts amperage only when constant current (CC) welding and does not adjust opencircuit voltage.

When Process Selector switch is in the MIG position, turn control clockwise to increase voltage. Voltmeter value changes as control knob is turned. Control can be adjusted while welding.

 When Welder Selector switch is in Welder

B position (single operator mode), weld amperage is two times the value selected by the Amperage/Voltage control. For example, if Amperage/Voltage control is set to 250 A, weld output is actually 500A.

6 Weld Meters

With Process Selector switch in the Stick/Tig position, meters read 0 (zero) with contactor off. Meters display actual output voltage and amperage with contactor on.

With Process Selector switch in the MIG position, voltmeter displays preset voltage with contactor off. Voltmeter and ammeter display actual output voltage and amperage with contactor on.

7 High Temperature Shutdown Light

Light goes on and weld output stops if weld rectifier gets too warm. Let unit cool before welding.

8 Remote Amperage/Voltage Control

Switch

For front panel control, place switch in Panel position. For remote control, place switch in Remote position, and connect remote device (see Section 5-17).

9 Output (Contactor) Switch

For front panel control of output, place switch in On (Hot) position. For remote control of output, place switch in Remote position, and connect remote device (see Section 5-17).

 Weld output terminals are energized

when Output (Contactor) switch is On and engine is running.

10 Polarity Switch (Optional)

 Do not switch under load.

Use switch to change polarity of weld output (see Sections 5-7 thru 5-14).

 Place optional Polarity switch in Reverse

position when using CV weld receptacle. There is no CV weld output when switch is in Straight position.

OM-494 Page 31

Page 36

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. 120 Volt And 240 Volt Duplex Receptacles

 Be sure equipment connected to the

240 V receptacles is GFCI-protected.

 Generator power is not affected by

position of Welder Selector switch.

 4 kVA/kW generator power output is

shared by all receptacles.

1 240 V 20 A AC Receptacle RC1 2 120 V 20 A AC GFCI Receptacle

GFCI 1 3 240 V 20 A AC Receptacle RC2 4 120 V 20 A AC GFCI Receptacle

GFCI 2 Receptacles supply 60 Hz single-phase

power at weld/power speed. If a ground fault is detected, the GFCI re-

ceptacle(s) circuit opens to disconnect the

faulty equipment and the GFCI Reset button pops out. Check for damaged tools, cords, plugs, etc. connected to the receptacle. Press button to reset receptacle and resume operation.

 At least once a month, run engine at

weld/power speed and press Test button to verify GFCI is working properly.

5 Circuit Breakers CB1 And CB2 6 Circuit Breakers CB3 And CB4 CB1 and CB2 protect RC1 and GFCI 1 from

overload. If CB1 or CB2 opens, RC1 does not work. 120 volts may still be present at RC1. If CB2 opens, GFCI 1 does not work. Press button to reset breaker.

CB3 and CB4 protect RC2 and GFCI 2 from overload. If CB3 or CB4 opens, RC2 does not work. 120 volts may still be present at

152364

190 376

RC2. If CB4 opens, GFCI 2 does not work. Press button to reset breaker.

 If a circuit breaker continues to open,

contact Factory Authorized Service Agent.

Maximum output from each 120 volt GFCI receptacle is 2.4 kVA/kW. Maximum output from each 240 volt duplex receptacle half is

4.0 kVA/kW. Total combined output from all receptacles

is 4 kVA/kW. EXAMPLE: If 12 A is drawn from RC1, only

9 A is available at GFCI 1: (240 V x 12 A) + (120 V x 9 A) = 4.0 kVA/kW

 Generator power is not affected by

weld output.

OM-494 Page 32

Page 37

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

 Stop engine before maintaining.

Recycle engine

fluids.

 See Engine Manual and Maintenance Label

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

Every

Hours

Every

Hours

Every

100

Hours

Every

250

Hours

Every

500

Hours

Every

1000

Hours

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

FUEL

WATER

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

 Air Cleaner Element  Weld Terminals

 Battery Terminals  Air Cleaner Hoses  Oil  Oil Filter

 Unreadable Labels Spark Arrestor

 Weld Cables

1/2 in.

(13 mm)

FUEL

SLUDGE

Reference

Section 5-5, 8-4

Section 8-3

Engine Manual, Section 8-9

Section 8-4, 8-10 and Engine Manual

 Fan Belt Tension  Inside Unit  FuelFilter  Drain Sludge

 Slip Rings*  Brushes*

Valve Clearance*

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Page 38

8-2. Maintenance Label

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Page 39

8-3. Servicing Air Cleaner

Keep nozzle 2 in (51 mm)

from element.

Blow Inspect

Optional

 Stop engine.  Do not run engine without air

41 3

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

 The air cleaner primary element can

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

risk of unwarrantable equipment damage when determining whether to clean or replace the primary element.

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

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

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

To clean air filter:

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

 Do not clean housing with air

hose.

Clean primary element with compressed air only.

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

Reinstall primary element and cap (dust ejector down).

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

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8-4. Servicing Fuel And Lubrication Systems

Under Left Side

Of Fuel Tank Behind

Control Panel

Valve Open

 Stop engine and let cool.

1 Oil Filter 2 Oil Drain Plug 3 Oil Drain Hose (Optional) 4 Oil Fill Cap 5 Primary Fuel Filter (Fuel/

Water Separator) 6 Petcock 7 Secondary Fuel Filter 8 Fuel Shutoff Valve Lever 9 Sludge Drain Plug

To change oil and filter:

See engine manual.

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:

Close shutoff valve and turn filter counterclockwise. Remove filter.

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

Inspect fuel line, and replace if cracked or worn.

To replace secondary fuel filter:

See engine manual.

To drain sludge from fuel tank:

 This procedure should only be

done by a Factory Authorized

Service Agent.

Remove Welder A (left) control panel to access sludge drain plug.

Put metal container under drain and remove plug. Reinstall plug when

sludge has drained. Reinstall control panel.

 After servicing, start engine

and check for fuel leaks.  Stop engine, tighten connec-

tions as necessary, and wipe

up spilled fuel.

Close doors.

Tools Needed:

OM-494 Page 36

3/8, 7/16, 3/4 in

Ref. 158 633-C / Ref. 190 377 / Ref. S-176 697

Page 41

8-5. Adjusting Engine Speed

Engine Speed

(No Load)

Weld/Power

RPM (HZ)

1850 (61.6)

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

1 High Speed Stop Screw 2 Lock Nut Loosen nut. Turn screw out (toward

front of engine) several turns. 3 Linkage 4 Lock Nuts Loosen nuts. Start engine and

move linkage until engine runs at weld/power speed. Tighten nuts.

 Stop engine.

5 Speed Control Lever Turn screw in until screw touches

lever. Tighten lock nut on screw. Close side door.

Right Side

Tools Needed:

3/8 in

8-6. Servicing Optional Ether Starting Aid

132

Ref. 045 768-B

 Stop engine.  Improper handling or expo-

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

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

Remove cylinder from valve.

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

valve fitting is clean. Replace cylinder according to

Section 5-16.

(935 g) (425 g)

Full Empty

15 oz33 oz

ether2 7/96 − 153 382-A / Ref. 190 377 / S-0692

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8-7. Checking And Replacing Alternator Belt

 Stop engine. To check belt tension:

Remove rear panel. 1 Alternator V-Belt 2 Crank Pulley 3 Alternator Pulley Place straight edge along top of pul-

leys. Pull down belt as far as it will go, then measure distance from belt to straight edge.

If measurement is less than 1/2 in (13 mm), belt is okay. If not okay, adjust belt tension.

To adjust belt tension:

4 Hex Nuts (2) 5 Alternator Bracket Loosen nuts. Pivot alternator until

belt is tight. Tighten nuts. Recheck tightness of belt. Readjust if necessary.

Replace belt if damaged or cracked.

To replace belt:

Loosen hex nuts and pivot alternator clockwise. Remove belt.

Install new belt, pivot alternator until belt is tight, and tighten nuts. Recheck tightness of belt after running

engine 15 minutes. Reinstall rear panel.

Tools Needed:

1/2, 11/16 in

1/2 in

(13 mm)

Max

158 632 / Ref. 190 377

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Page 43

8-8. Resetting Fan Belt Safety Shutdown

 Stop engine.

1 Cooling Fan V-Belt See engine manual to replace or

tighten belt. If belt breaks or becomes loose,

safety shutdown stops engine. Correct problem, then reset safety

shutdown as follows: 2 Rod 3 Stop 4 Bracket 5 Handle Pull handle towards front of unit un-

til stop snaps in position behind bracket.

Close door.

Tools Needed:

3/8 in

Right Side

Pull Handle To

Reset Shutdown

158 715 / Ref. 158 632 / Ref. 190 377

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Page 44

8-9. Inspecting And Cleaning Optional Spark Arrestor Muffler

 Stop engine and let cool.

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

covering cleanout hole. 3 Exhaust Pipe Start engine and run several min-

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

 Stop engine and let cool.

Reinstall cleanout plug.

Tools Needed:

3/8 in

8-10. Checking Generator Brushes

1/2 in (13 mm)

Minimum Length

Replace

Damaged

Brushes

1-1/8 in (28.6 mm)

New Length

Ref. 800 633-B / Ref. 190 377

 Stop engine and let cool.

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

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

material is at or near minimum length.

Ref 217 359-A / S−0233−A

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Page 45

8-11. Circuit Protection

Tools Needed:

 Stop engine.

 When a circuit breaker or fuse opens,

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

1 Fuse F1 2 Fuse F2 3 Fuse F3 4 Fuse F4 Open front panel.

Fuse F1 protects the exciter excitation winding. If F1 opens, there is no weld or generator power output on both sides.

Fuse F2 protects the exciter main field excitation winding. If F2 opens, there is no weld output on both sides.

Fuse F3 protects Welder A (left) control board PC1. If F3 opens, Welder A (left) weld output stops.

Fuse F4 protects Welder B (right) control

board PC1. If F4 opens, Welder B (right) weld output stops.

5 Circuit Breaker CB5 6 Circuit Breaker CB6 7 Circuit Breaker CB7 8 Circuit Breaker CB8 Circuit Breaker CB5 protects the 24 volt

and 115 volt ac output to Welder A (left) remote receptacle RC9. If CB5 opens, Welder A (left) RC9 24 and 115 volt ac output stops.

Circuit Breaker CB6 protects the 24 volt and 115 volt ac output to Welder B (right) remote receptacle RC8. If CB6 opens, Welder B (right) RC8 24 and 115 volt ac output stops.

Circuit Breaker CB7 protects field current regulator board PC4. If CB7 opens, weld and generator power output on both sides stops.

Circuit Breaker CB8 protects the generator field flashing circuit. If CB8 opens, weld and

Ref. 802 300 / Ref. 802 292-A

generator power output may continue if generator maintains excitation. Weld and generator power output stops if generator requires field flashing circuit to restore excitation.

Press button to reset circuit breaker. 9 Fuses F11, F12, F13, F21, F22, F23 These fuses protect the weld stator wind-

ings. If fuse F11, F12, or F13 opens, Welder B (right) side output is erratic or low. If fuse F21, F22, or F23 opens, Welder A (left) side output is erratic or low.

10 Thermostats TP3 And TP4 (Internal −

Not Shown)

Thermostat TP3 protects Welder A (left) SR2 rectifier and TP4 protects Welder B (right) SR3 rectifier from overheating. If TP3 or TP4 opens, Welder A (left) or Welder B (right) weld output stops and the High Temp. Shutdown light goes on. Wait fifteen minutes for module to cool and thermostat to automatically reset. Reduce amperage, voltage, or duty cycle before welding.

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8-12. Troubleshooting

A. Welding

Trouble Remedy

No weld output on either side; generator power output okay at ac receptacles.

No weld output on either side and no generator power output at ac receptacles.

No Welder A (left) weld output; Welder B (right) weld output okay.

Place Output (Contactor) switches in On (Hot) position, or place switches in Remote position and connect remote contactors to remote receptacles RC8 and RC9 (see Section 6-3).

Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP3 and TP4 to reset (see Section 8-11).

Check position of Process Selector switches and Welder Selector switch. All weld output stops if either Process Selector switch is placed in CV position when Welder Selector switch is in Welder B position (see Sections 6-1 and 6-3).

Check fuse F2, and replace if open (see Section 8-11). Have Factory Authorized Service Agent check field current regulator board PC4.

Have Factory Authorized Service Agent check field current regulator board PC4 and Welder Selector switch S2.

Disconnect equipment from generator power receptacles during start-up.

Check fuse F1, and replace if open (see Section 8-11).

Reset circuit breakers CB7 and/or CB8 (see Section 8-11).

Have Factory Authorized Service Agent check brushes and slip rings, field excitation circuit, rotor, stator, and field current regulator board PC4.

Check fuse F3, and replace if open (see Section 8-11).

Check position of Welder Selector switch. Welder A (left) weld output stops when Welder Selector switch is placed in Welder B position (see Section 6-1).

Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP3 to reset (see Section 8-11).

No Welder B (right) weld output; Welder A (left) weld output okay;

Low Welder A (left) weld output; Welder B (right) output okay.

Low Welder B (right) weld output; Welder A (left) weld output okay.

OM-494 Page 42

Have Factory Authorized Service Agent check Welder A (left) contactor circuit.

Check fuse F4, and replace if open (see Section 8-11).

Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP4 to reset (see Section 8-11).

Have Factory Authorized Service Agent check Welder B (right) contactor circuit.

Check position of Process Selector switch (see Section 6-3).

Increase Amperage/Voltage control setting.

Check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have Factory Authorized Service Agent check main rectifier SR2.

Have Factory Authorized Service Agent check main rectifier SR2, synchronization transformers T5, T6 and T7, and control board PC1.

Check position of Process Selector switch (see Section 6-3).

Increase Amperage/Voltage control setting.

Check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have Factory Authorized Service Agent check main rectifier SR3.

Have Factory Authorized Service Agent check main rectifier SR3, synchronization transformers T8, T9 and T10, and control board PC5.

Page 47

Trouble Remedy

Low weld output on both sides. Check engine speed, and adjust if necessary (see Section 8-5).

Check position of Process Selector switch(s) (see Section 6-3).

Increase Amperage/Voltage controls settings.

Have Factory Authorized Service Agent check field current regulator board PC4.

High weld output on both sides. Have Factory Authorized Service Agent check field current regulator board PC4.

Erratic weld output on either side. Check and tighten connections inside and outside unit.

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Check Process Selector switch(s) connections and contacts.

Welder A (left) side: check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have Factory Authorized Service Agent check main rectifier SR2.

Welder B (right) side: check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have Factory Authorized Service Agent check main rectifier SR3.

Have Factory Authorized Service Agent check Welder Selector switch S2.

Low open-circuit voltage on both sides. Check engine speed, and adjust if necessary (see Section 8-5).

Have Factory Authorized Service Agent check field current regulator board PC4.

Low open-circuit voltage on either side. Increase Amperage/Voltage control setting.

Welder A (left) side: check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have Factory Authorized Service Agent check main rectifier SR2.

Welder B (right) side: check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have Factory Authorized Service Agent check main rectifier SR3.

Have Factory Authorized Service Agent check main rectifiers SR2 and SR3, synchronization transformers T5 thru T10, and control board PC1 or PC5.

No control of weld output on either side.

No voltage control on either side; opencircuit voltage present.

Wire feeder does not work (either side). Reset Welder A (left) circuit breaker CB5 or Welder B (right) circuit breaker CB6 (see Section 8-11).

Place A/V Control switch in Panel position, or place switch in Remote position and connect remote control to remote receptacle RC8 or RC9 (see Sections 5-17 and 6-3).

Have Factory Authorized Service Agent check control board PC1 or PC5.

Repair or replace remote device.

Place A/V Control switch in Panel position, or place switch in Remote position and connect remote control to remote receptacle RC8 or RC9 (see Sections 5-17 and 6-3).

Check connections to Remote receptacle RC8 and RC9.

Have Factory Authorized Service Agent check control board PC1 or PC5.

Check connections to Remote 14 receptacle RC8 (see Section 5-17).

Place optional Polarity switches in Reverse position. There is no CV weld output when Polarity switch is in Straight position.

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

Repair or replace wire feeder.

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B. Generator Power

Trouble Remedy

No output at generator power ac receptacles.

High or low output at generator power ac receptacles.

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

Press GFCI reset button on 120 volt GFCI receptacles (see Section 7-1).

Check fuse F1, and replace if open (see Section 8-11).

Check receptacle(s) for continuity and proper connections. Replace receptacle(s) if necessary.

Have Factory Authorized Service Agent check brushes and slip rings.

Check engine speed, and adjust if necessary (see Section 8-5).

C. Engine

Trouble Remedy

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

Check battery connections and tighten if necessary.

Have Factory Authorized Service Agent check Engine Start Button PB1.

Engine cranks but does not start. Check fuel level (see Section 5-5).

Open fuel valve (see Section 5-5).

Check battery voltage, and replace battery if necessary.

Check blower fan V-belt according to engine manual. Safety shutdown stops engine if belt is broken or loose (see Section 8-8).

Check engine charging system according to engine manual.

See engine manual.

Engine suddenly stops. Check blower fan V-belt according to engine manual. Safety shutdown stops engine if belt is broken or

Battery discharges between uses. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.

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

loose (see Section 8-8).

See engine manual.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator and connections according to engine manual.

Dry engine (see Section 10).

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Page 49

Notes

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Page 50

SECTION 9 − ELECTRICAL DIAGRAMS

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Figure 9-1. Circuit Diagram For Welding Generator

Page 51

OM-494 Page 47

210 657-A

Page 52

10-1. Wetstacking

SECTION 10 − RUN-IN PROCEDURE

 Do not perform run-in

procedure at less than 20

volts weld output and do not

exceed duty cycle or equip-

ment damage may occur.

1 Welding Generator Run diesel engines near rated volt-

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

 Do not idle engine longer than

necessary. Piston rings seat

faster if engine runs at weld/

power rpm, and the welding

generator is kept loaded during

run-in.

2 Engine Exhaust Pipe Wetstacking is unburned fuel and

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

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

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

run_in3 8/01

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Page 53

10-2. Run-In Procedure Using Load Bank

 Stop engine.  Do not touch hot exhaust

pipe, engine parts, or load bank/grid.

 Keep exhaust and pipe away

from flammables.

 Do not perform run-in

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

1 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 Welder Selector switch in

Welder B position (600 Amps), A/V control in minimum position, and both Process Selector switches in Stick/TIG position.

3 Weld Cables Connect load bank to generator

Welder B (right) 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 350 Amps at 40 volts.

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

 Check oil level frequently dur-

ing run-in; add oil if needed.

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

 Stop engine and let cool.

4 Engine Exhaust Pipe Repeat procedure if wetstacking is

present.

S-0683

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10-3. Run-In Procedure Using Resistance Grid

 Stop engine.  Do not touch hot exhaust

pipe, engine parts, or load bank/grid.

 Keep exhaust and pipe away

from flammables.

 Do not perform run-in

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

1 Resistance Grid Use grid sized for generator rated

output.

Turn Off grid. 2 Welding Generator

Place Welder Selector switch in Welder B position (600 Amps), A/V control in minimum position, and both Process Selector switches in Stick/TIG position.

3 Weld Cables Connect grid to generator Welder B

(right) 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 350 Amps at 40 volts.

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

 Check oil level frequently dur-

ing run-in; add oil if needed.

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

 Stop engine and let cool.

6 Engine Exhaust Pipe Repeat procedure if wetstacking is

present.

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S-0684

Page 55

SECTION 11 − GENERATOR POWER GUIDELINES

NOTE

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

11-1. Selecting Equipment

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

 Do not use 2-prong plug un-

less equipment is double insulated.

11-2. Grounding Generator To Truck Or Trailer Frame

GND/PE

Be sure equipment has this symbol and/or wording.

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

 Always ground generator

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

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied) 3 Metal Vehicle Frame Connect cable from equipment

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

 If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

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

 Bed liners, shipping skids, and some running

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

S-0854

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11-3. Grounding When Supplying Building Systems

1 2

GND/PE

Use ground device as stated

in electrical codes.

1 Equipment Grounding

Terminal 2 Grounding Cable Use #10 AWG or larger insulated

copper wire. 3 Ground Device

 Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

11-4. How Much Power Does Equipment Require?

AMPERES x VOLTS = WATTS

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

requirement in watts.

4.5 A x 115 V = 520 W

The load applied by the drill is 520 watts.

VOLTS 115 AMPS Hz

4.5 60

ST-800 576-B

1 Resistive Load A light bulb is a resistive load and

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

sistive load and requires approximately six times more power while starting the motor than when running (see Section 11-8).

3 Rating Data Rating shows volts and amperes, or

watts required to run equipment.

OM-494 Page 52

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

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

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

S-0623

Page 57

11-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

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

Capacitor Start-Induction Run 1/3 HP 2020 720

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

1 HP 6100 1600

1-1/2 HP 8200 2200

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

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

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

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

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

Farm/Home Equipment Rating Starting Watts Running Watts

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

1-1/2 HP 8200 2200

2 HP 10550 2850 3 HP 15900 3900

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

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

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

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Page 58

11-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

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

Circular Saw 6-1/2 in 500 500

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

Table Saw 9 in 4500 1500

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

8 in 3900 1400

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

1 HP 6000 1500

1-1/2 HP 8200 2200

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

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

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

Metal Halide 313 250

Mercury 1000

Sodium 1400

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

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

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

2-1/2 HP 1300 1300

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Page 59

11-8. Power Required To Start Motor

4 1

VOLTS AMPS

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GH JKLMNP

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

kVA/HP x HP x 1000

VOLTS

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

HP motor with a motor start code of M.

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

11.2 x 1/4 x 1000 230

= 12.2 A

CODE 60

Starting the motor requires 12.2 amperes.

AC MOTOR

230 2.5

1/4

= STARTING AMPERAGE

Hz PHASE

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

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

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

age (see example). Welding generator amperage out-

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

S-0624

11-9. How Much Power Can Generator Supply?

1 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

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11-10. Typical Connections To Supply Standby Power

 Properly install and ground this equipment according to

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

1234

Utility

Electrical

Service

Transfer Switch

Essential

Loads

Fused

Disconnect

Switch

(If Required)

Welding

Generator

Output

 Have only qualified persons perform

these connections according to all applicable codes and safety practices.

 Properly install and ground this

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

 Customer-supplied equipment is re-

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

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

Notes

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

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

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

required by electrical code. 4 Welding Generator Output Generator output voltage and wiring must be

consistent with regular (utility) system voltage and wiring.

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

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

5 Essential Loads

Generator output may not meet the electrical requirements of the premises. If generator does not produce enough output to meet all requirements, connect only essential loads (pumps, freezers, heaters, etc. − See Section 11-4).

OM-494 Page 56

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at the beginning of this manual.

Page 61

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

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

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

Current

(Amperes)

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

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

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

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

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

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

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

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

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

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

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

Load (Watts) 4 6 8 10 12 14

Current

(Amperes)

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

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

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

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

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

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

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

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

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

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

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

*Conductor size is based on maximum 2% voltage drop

Load (Watts) 4 6 8 10 12 14

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

OM-494 Page 57

Page 62

 Hardware is common and

not available unless listed.

96−SEE FIG 12-2

SECTION 12 − PARTS LIST

103

102

101

100

12 13

25−SEE FIG 12-4

35 36

37 38

OM-494 Page 58

Figure 12-1. Main Assembly

Page 63

57−SEE FIG 12-3

78−SEE FIG 12-4

802 317-D

OM-494 Page 59

Page 64

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-1. Main Assembly

1 605 288 FITTING, pipe galv plug sqhd .250NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 070 010 BOLT, J stl .250-20 x 2.750 pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 088 696 STRAP, hold down fuel tank 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 134 771 PLUG, protective .640sq 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 184 675 TANK, fuel 22.3gal (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 182 022 CAP, fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 020 185 FITTING, pipe brs elbow st 1/8NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 053 525 FITTING, hose brs barbed M 5/16tbg x 1/8NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 172 071 CLAMP, hose .520-.605clp dia slfng 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 134 835 HOSE, SAE .312 ID x .560 OD (order by ft) 9ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 097 507 STRIP, rbr adh back .125 x 1.000 x 20.500 60 duro 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 175 432 VALVE, shut-off fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 039 599 FITTING, brs barbed M 5/16 tbg x 1/4 NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 +048 227 UPRIGHT, base front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 170 689 FRAME, mtg reactor and fuel tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 +170 617 UPRIGHT, base center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 017 479 SEAL, weather lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 R3, R5 097 459 RESISTOR, WW fxd 375W 20 ohm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 108 081 TERMINAL PROTECTOR, battery post mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 182 276 CABLE, bat pos 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 208 353 HOLD DOWN, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 032 453 CABLE, bat neg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 190 896 BATTERY, stor 12v 660 crk 110 rsv gp 24 low 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 010 460 STUD, stl .312-18 x 10.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 SR2, SR3 Figure 12-5 RECTIFIER ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 176 697 LABEL, fuel shut-off 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 145 282 FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 083 859 BRACKET, mtg fuel filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 Deleted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 202 242 BASE, fuel filter assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 192 744 SEPARATOR, fuel filter & water 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 135 205 NUT, 625-11 .94 hex .76H stl pld 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 116 707 SUPPORT, front engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 119 849 SCREW, 625-11 x 4.00 hexhd pln gr 5 pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 071 731 WASHER, flat stl .656 ID x 2.250 OD x .187thk 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 071 890 RETAINER, mount eng/gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 071 730 TUBING, stl .875 OD x 12ga wall x 2.500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 072 848 MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 50 dur 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 010 875 CLAMP, muffler 2.000 dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 105 734 PIPE, muffler extension elbow 1.875 OD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 176 232 BAFFLE, air muffler exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 048 216 BRACKET, mtg breather 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 +105 909 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 192 041 LABEL, use diesel fuel only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 035 968 WASHER, flat rbr 3.625 ID x 5.875 OD x .062thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 158 610 LABEL, warning electric shock 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 168 385 LABEL, warning battery explosion 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 +192 313 DOOR, side LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 222 513 LABEL, warning falling equipment can cause serious 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 117 257 PANEL, end engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 +192 314 DOOR, side RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 181 642 LABEL, diesel engine maintenance 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 004 130 BRACKET, support door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 087 341 BUMPER, door 1.000 OD x .750 high 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 087 336 LATCH 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 027 434 LABEL, welder will not start by applying power to terminals 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 Figure 12-3 SIDE CONTROL PANELS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 023 313 CLAMP, hose 3.250-3.000 clp dia slftg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 201 547 HOSE, air cleaner w/spring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 010 863 CLAMP, hose 2.062 − 3.000 clp slftg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-494 Page 60

Quantity

Page 65

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-1. Main Assembly (Continued)

61 189 764 AIR CLEANER, intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

203 462 BRACKET, mtg air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 165 785 HOSE, air cleaner 2.437 ID 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 048 213 BAFFLE, air intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

194 467 WASHER, flat (for baffle) 6.25 ID x 11.50 OD x .62 T buna 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 LEVER, trip shutdown (included w/engine − see engine parts list) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 SPRING (included w/engine − see engine parts list) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 181 634 ENGINE, dsl electric (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 087 371 ROD, shutdown 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*064 677 FILTER, oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*062 342 FILTER, fuel primary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*064 686 FILTER, fuel secondary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*064 690 BELT, blower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 070 661 ROD, speed control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 151 969 SWITCH, pressure 4PSI N/O 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 ♦047 361 FITTING, banjo 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 ♦089 351 FITTING, pipe brs plug hexhd 1/2NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 ♦192 197 BRACKET, mounting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 ♦008 114 HOSE, oil w/fittings 17.500 lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 ♦047 234 BOLT, banjo 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦047 235 WASHER, oil seal copper 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 127 994 BALL JOINT, .250-28 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 162 740 STUD, stl .250-28 x 45.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 083 476 MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 60 dur 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 Figure 12-4 GENERATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 225 120 LABEL, warning moving parts can cause injury 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 176 236 BAFFLE, air outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 CLAMP, muffler (included with engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 105 733 PIPE, muffler extension elbow 1.875 OD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 165 739 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 191 446 EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) 2.1ft. . . . . . . . . . . . . . . . . . . . . . . .

85 173 352 EXTRUSION, rubber clamp/bulb (order by ft) 2.4ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 192 305 TRAY, base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 176 167 NUT, 250-20 acorn nylon 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 192 303 ANGLE, mtg stabilizer 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 Z1, Z2 192 296 STABILIZER 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 205 791 BRACKET, mtg fuse assembly (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91 204 965 STRIP, insulation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 026947 STAND-OFF, insul .250-20 x 1.0 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 F11-13, F21-23 027 267 FUSE, link 300 A 250 volt 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 192 304 PANEL, front lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 223 379 LABEL, warning general precautionary CSA 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96 Figure 12-2 FRONT PANEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 175 256 INSULATOR, side rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98 192 300 SHROUD, generator LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 T2, T4 192 371 TRANSFORMER, 115V pri 24VCT 8A w/leads 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 192 301 SHROUD, generator RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 168 829 TRANSDUCER, current 1000A module max open loop 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 192 299 SHROUD, generator center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 194 021 CAPACITOR ASSEMBLY, (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

162 817 BUS BAR, capacitor 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C15, C20 163 535 CAPACITOR, elctlt 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R4, R6 140 002 RESISTOR, WW fxd 10W 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

162 799 BRACKET, mtg capacitors 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-494 Page 61

Page 66

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-1. Main Assembly (Continued)

201 915 KIT, label (includes safety and informational labels) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 916 KIT, label (includes safety and informational labels) . . . . . . . . . . . . . . . . . . . .

(Models w/opt. Polarity Switch) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+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.

 Hardware is common and

not available unless listed.

OM-494 Page 62

802 318-C

Figure 12-2. Front Panel

Page 67

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-2. Front Panel (Figure 12-1 Item 96)

1 209056 COVER, receptacle w/gasket 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 190 323 BOOT, circuit breaker 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Deleted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 PLATE, ident control rating (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 190 375 NAMEPLATE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 216270 PANEL, aux power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 334 HARNESS, wiring aux power panel (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 GFCI1,2 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 2. . . . . . . . . . . . . . . . . . . . . . . . . .

8 CB1-4 093 996 CIRCUIT BREAKER, man reset 1P 20A 250VAC frict 4. . . . . . . . . . . . . . . . . . . . . . . . . . .

9 RC1, RC2 193 257 RECEPTACLE, str dx grd 2P3W 15/20A 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 R10 189 699 RESISTOR, WW tap 375W 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 038 620 LINK, jumper term blk 30A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 TE1,2 038 621 BLOCK, term 30A 4 pole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 T5 - 10 210 636 TRANSFORMER, control 6VA 120VCT 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 PC4 191 255 CIRCUIT CARD ASSEMBLY, field current regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 083 147 GROMMET, SCR NO 8/10 panel 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 192 332 PANEL LAYOUT, mtg component 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 CB7,8 139 266 CIRCUIT BREAKER, man reset 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 1T,2T 190 210 BLOCK, term 5-3-3 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 083 030 STUD, brs .250-20 x 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 010 381 CONNECTOR, rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 T1, T3 192 367 TRANSFORMER, control 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 184 649 HOLDER, fuse mintr .250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 F3,4 *012 643 FUSE, mintr gl slo-blo 1A, 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 F1,2 *125 847 FUSE, mintr cer slo-blo 12A, 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 129 351 SCREW, 008−32x .50 hexwhd.34d stl pld slffmg tap−rw 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 177 136 CLAMP, capacitor 1.375dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 C1 087 110 CAPACITOR, elctlt 240 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 SR1 035 704 RECTIFIER, integ bridge 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

195 702 HARNESS, wiring componet panel (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188 512 SEAL, wire univ 6P/S 3 row 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 651 SEAL, wire univ 9P/S 3 row 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC13,21 116 045 HOUSING, plugs and pins 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG17 135 275 HOUSING, plugs and pins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC19, PLG20 168 071 HOUSING, plugs and pins 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 S2 192 292 SWITCH, paralleling 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 006 HARNESS, engine (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 PB1 046 433 SWITCH, PB MC NO SPST 35A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 STUD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 HM 145 247 METER, hour 12-24VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 205 744 ROD, engine shutoff assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 019 603 KNOB, ball 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 PL1 188 266 LIGHT, ind red lens 13V (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 082 788 HOLDER, light ind only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 048 155 BULB, incand min 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 082 789 LENS, light ind red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 010 647 PIN, spring CS .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 111 785 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 PLATE, ident control rating (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 192 316 PANEL, front control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts.

OM-494 Page 63

Page 68

 Hardware is common and

not available unless listed.

3231

OM-494 Page 64

802 320-A

Figure 12-3. Side Control Panels − Welder B (Right) Side Shown

Page 69

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-3. Side Control Panels (Figure 12-1 Item 57)

1 +192 330 PANEL, side output RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+192 325 PANEL, side output LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 027 434 LABEL, welder will not start by applying power to terminals 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 010 828 HANDLE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 086 074 TUBING, cop .540 ID x .123 wall x .562 − welder A (left) side only 1. . . . . . . . . . . . . . . . . . . . . . . .

5 S1, S9 204 903 SWITCH, mode single w/ dust cover (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

163 557 SWITCH, mode single 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202 881 COVER, dust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 193 337 ELECTRONICS BOX 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PC5 204 832 CIRCUIT CARD ASSEMBLY, welder B (right) side control 1. . . . . . . . . . . . . . . . . . . . . . . . .

PC1 204 835 CIRCUIT CARD ASSEMBLY, welder A (left) side control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 218 HARNESS, wiring control box welder B (right) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CR3 000 770 RELAY, encl 24VDC 3PDT 10A/120VAC 11 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 GRD 185 011 STUD, primary board brs 10-32 x 1.592 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 S8,10,11 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 R7,8 035 897 POTENTIOMETER, cp std slot 1t 2w 1k linear 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 LS3, 4 089 645 SWITCH, lim 11A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG27 131 056 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 651 SEAL, wire univ 9P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG20 168 071 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG9,26 148 439 CONNECTOR, housing plug pins and sockets 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG12 152 249 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 153 501 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC22 168 845 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC23 168846 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8 169 240 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 208 HARNESS, wiring control box welder A (left) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR2 000 770 RELAY, encl 24VDC 3PDT 10A/120VAC 11 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GRD 185 011 STUD, primary board brs 10-32 x 1.592 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S3,6,7 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R1,8 035 897 POTENTIOMETER, cp std slot 1t 2w 1k linear 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LS1,2 089 645 SWITCH, lim 11A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG18 131 056 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 651 SEAL, wire univ 9P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG19 168 071 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4,11 148 439 CONNECTOR, housing plug pins and sockets 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG5 152 249 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 153 501 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC6 168 845 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC7 168846 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 169 240 CONNECTOR, housing plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 PC2, PC6 178 130 CIRCUIT CARD ASSEMBLY, digital meter 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 165 316 STAND-OFF, No. 6-32 x .875 lg .312 hex nyl 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

136 343 SCREW, K50 x 20 soc hd trx stl pld slftpg 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 097 924 KNOB, pointer 1.625dia x .250 ID 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 021 385 BOOT, toggle switch lever 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 097 922 KNOB, pointer .875dia x .250 ID 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 148 956 HANDLE, switch 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 NAMEPLATE (order by model and serial number) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 162 815 PANEL, front upper 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 161 297 CAM, switch selector 2posn 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 170 391 CONNECTOR, circ protective cap 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 039 047 TERMINAL, pwr output red (consisting of) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 049 TERMINAL BOARD, red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 044 BUS BAR, term bd 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 976 SCREW, 500-13 x 1.50 hexhd 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 880 NUT, 500-13 x .75 hex .31H 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-494 Page 65

Quantity

Page 70

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-3. Side Control Panels (Continued)

24 039 046 TERMINAL, pwr output black (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 045 TERMINAL BOARD, black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 044 BUS BAR, term bd 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 976 SCREW, 500-13 x 1.50 hexhd 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 880 NUT, 500-13 x .75 hex .31H 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 192 494 BUS BAR, connecting 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 192 493 STAND-OFF, bus bar 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 C2,4,5,21,22,23 136 736 CAPACITOR, cer disc .1uf 500VDC 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 336 HARNESS, wiring unit welder B (right) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 4T 190 210 BLOCK, term 5-3-3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 CB6 139 266 CIRCUIT BREAKER, man reset 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 RC9 134 735 CONNECTOR, circ MS/CPC 14skt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 PC7 181 261 CIRCUIT CARD ASSEMBLY, filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG24 115 094 HOUSING, plug and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG22 168 847 HOUSING, plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG23 152 249 HOUSING, plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG21 135 556 HOUSING, plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188 512 SEAL, wire univ 6P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 337 HARNESS, wiring unit welder A (left) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3T 190 210 BLOCK, term 5-3-3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB5 139 266 CIRCUIT BREAKER, man reset 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC8 134 735 CONNECTOR, circ MS/CPC 14skt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC3 181 261 CIRCUIT CARD ASSEMBLY, filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG14 115 094 HOUSING, plug and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 168 847 HOUSING, plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 152 249 HOUSING, plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG13 135 556 HOUSING, plug pins and sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188 512 SEAL, wire univ 6P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 165 316 STAND-OFF, No. 6-32 x .875 lg .312 hex nyl 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145 217 SCREW, K40 x 12 pan hd phl stl pld slftpg 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 ♦059 773 HANDLE, switch 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 ♦010 647 PIN, spring 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦091 067 SWITCH, polarity 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦168 077 CONNECTOR, tw lk insul fem (Dinse-type) to output stud 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦199 123 LABEL, component identification master polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦199 124 LABEL, component identification slave polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 PL2, PL3 159 522 LED, yellow 2.1v 20 ma 45.0 mcd panel mtg .250 hole 2. . . . . . . . . . . . . . . . . . . . . . .

36 159 036 LENS, led clear panel mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts.

♦OPTIONAL

OM-494 Page 66

Page 71

 Hardware is common and

not available unless listed.

Ref. 048 456-E

Figure 12-4. Generator

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-4. Generator (Figure 12-1 Item 78)

1 *151 299 BRUSH, contact elect clrg .375 x .750 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 188 387 BRUSHHOLDER/BRACKET ASSEMBLY, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 600 270 HOLDER, brush 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 152 044 CAP, holder brush 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 173 066 BRACKET, mtg brushholder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 +205 600 STATOR, generator (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 039 207 BAFFLE, air generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 192 286 ROTOR, generator (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 024 617 RING, retaining external 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 053 390 BEARING, ball 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 083 748 FAN, rotor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 225 120 LABEL, warning moving parts can cause injury 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-494 Page 67

Quantity

Page 72

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-4. Generator (Continued)

13 195 704 STATOR, exciter aux pwr 120/240 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 173 068 ENDBELL, generator (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 143 220 O-RING 2.859ID x .139CS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts.

 Hardware is common and

not available unless listed.

802 319

Figure 12-5. Rectifier Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-5. Rectifier (Figure 12-1 Item 25)

1 205 613 RECTIFIER ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203 001 RECTIFIER, Si Diode (One Side Service kit W/Varnish Coating) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1, PLG2 158 720 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-494 Page 68

Page 73

Notes

OM-494 Page 69

Page 74

Page 75

Warranty Questions?

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

Your distributor also gives you ...

Service

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

Support

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

Effective January 1, 2005

(Equipment with a serial number preface of “LF” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers * Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources * Plasma Arc Cutting Power Sources * Semi-Automatic and Automatic Wire Feeders * Inverter Power Sources (Unless Otherwise Stated)

* Water Coolant Systems (Integrated)

* Intellitig * Maxstar 150 * Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* DS-2 Wire Feeder * Motor Driven Guns (w/exception of Spoolmate

Spoolguns) * Process Controllers * Positioners and Controllers * Automatic Motion Devices * RFCS Foot Controls * Induction Heating Power Sources and Coolers * Water Coolant Systems (Non-Integrated) * Flowgauge and Flowmeter Regulators (No Labor) * HF Units * Grids * Maxstar 85, 140 * Spot Welders * Load Banks * Arc Stud Power Sources & Arc Stud Guns * Racks * Running Gear/Trailers * Plasma Cutting Torches (except APT & SAF

Models) * Field Options

(NOTE: Field options are covered under True

Blue® for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets * APT & SAF Model Plasma Cutting Torches * Remote Controls * Accessory Kits * Replacement Parts (No labor) * Spoolmate Spoolguns * Canvas Covers

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. (Exception: brushes, slip rings, and relays are covered on Bobcat, Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

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

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

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

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

miller_warr 1/05

Page 76

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: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125

European Headquarters − United Kingdom

Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066

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.