Miller Electric Miller DU-OP User Manual

OM-225590C

2007−11

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

From Miller to You

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

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

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

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

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

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

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

Working as hard as you do

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

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

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

Mil_Thank 4/05

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3-1. Symbols And Definitions 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Description 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Weld, Power, And Engine Specifications 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Dimensions, Weights, And Operating Angles 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4-5. AC Generator Power 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Duty Cycle And Overheating 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Volt-Ampere Curves 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Installing Welding Generator 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Activating The Dry Charge Battery (If Applicable) 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Connecting The Battery 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Installing Exhaust Pipe 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Engine Prestart Checks 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Safety Information For Connecting To Weld Output Terminals 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables 22 . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable 23 . . . . . . . . . . . . . . . . . . .

5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables 24 . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable 25 . . . . . . . . . . . . . . . . . . . . . . . . .

5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables 26 . . . . . . . . . . . . . . . .

5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable 27 . . . . . . . . . . . . . . . . .

5-14. Making Single Operator CC Weld Connections 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15. Selecting Weld Cable Sizes* 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-16. Installing Ether Cylinder (Optional Ether Starting Aid) 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-17. Remote 14 Receptacle Information 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-18. Remote 14 Receptacle Connections 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING THE WELDING GENERATOR 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Engine Controls 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Weld Controls (See Section 6-3) 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Weld Control Descriptions (See Section 6-2) 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − OPERATING AUXILIARY EQUIPMENT 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. 120 Volt And 240 Volt Duplex Receptacles 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 8 − MAINTENANCE & TROUBLESHOOTING 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Routine Maintenance 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Maintenance Label 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Servicing Air Cleaner 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Servicing Fuel And Lubrication Systems 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Adjusting Engine Speed 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Servicing Optional Ether Starting Aid 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Priming Fuel System 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8. Inspecting And Cleaning Optional Spark Arrestor Muffler 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9. Checking Generator Brushes 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10. Circuit Protection 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-11. Troubleshooting 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − ELECTRICAL DIAGRAMS 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − RUN-IN PROCEDURE 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Wetstacking 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Run-In Procedure Using Load Bank 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Run-In Procedure Using Resistance Grid 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − GENERATOR POWER GUIDELINES 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − PARTS LIST 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom_2007−04

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

1-1. Symbol Usage

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

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

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

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

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

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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

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

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

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

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

there is a danger of falling.

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

unit.

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

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

 Disconnect input power or stop engine before installing or

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

 Properly install and ground this equipment according to its

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

 Indicates special instructions.

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

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

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

 When making input connections, attach proper grounding conduc-

tor first − double-check connections.

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

and sparks.

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

replace cord immediately if damaged — bare wiring can kill.

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

with a separate cable.

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

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

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

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

or worktable as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop­ping engine.

 Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

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

ment.

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

lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

 Welding, chipping, wire brushing, and grinding

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

 Wear approved safety glasses with side shields even under your

welding helmet.

OM-225 590 Page 1

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

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

arc to remove welding fumes and gases.

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

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

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

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

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

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

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

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

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

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

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

gas, or liquid vapors (such as gasoline).

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

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

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

contact tip when not in use.

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

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

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

from your person before doing any welding.

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

glowing embers, and flames.

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

pass them.

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

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

NOISE can damage hearing.

BUILDUP OF GAS can injure or kill.

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

proved air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays that

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

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

 Wear approved safety glasses with side shields under your

helmet.

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

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

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

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

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums,

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

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

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

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

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

easily go through small cracks and openings to adjacent areas.

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

cause fire on the hidden side.

Noise from some processes or equipment can dam­age hearing.

 Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect Implanted
Medical Devices.

 Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

 Implanted Medical Device wearers should consult their doctor

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

CYLINDERS can explode if damaged.

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

 Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

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

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

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

use or connected for use.

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

ber of persons to lift and move cylinders.

 Read and follow instructions on compressed gas cylinders,

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

OM-225 590 Page 2

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND.

 Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

 Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

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

FUEL can cause fire or explosion.

 Stop engine and let it cool off before checking or

adding fuel.

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

any sparks or open flames.

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

MOVING PARTS can cause injury.

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

closed and securely in place.

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

guards for maintenance and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

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

parts.

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

finished and before starting engine.

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

keep engine from kicking back or starting.

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

components.

STEAM AND HOT COOLANT can burn.

 If possible, check coolant level when engine is

cold to avoid scalding.

 Always check coolant level at overflow tank, if

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

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

flow tank, follow the next two statements.

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

completely removing cap.

Using a generator indoors CAN KILL
YOU IN MINUTES.

 Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

 NEVER use inside a home or garage, EVEN IF

doors and windows are open.

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

vents.

BATTERY ACID can BURN SKIN and EYES.

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

ENGINE HEAT can cause fire.

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

surfaces or flammables.

 Keep exhaust and exhaust pipes way from

flammables.

HOT PARTS can cause severe burns.

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

ment.

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

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

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can
cause serious injury or death.

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

COMPRESSED AIR can cause injury.

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

EXHAUST SPARKS can cause fire.

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

required areas — see applicable codes.

TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.

 Release air pressure from tools and system be-

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

OM-225 590 Page 3

HOT METAL from air arc cutting and

READ INSTRUCTIONS.

gouging can cause fire or explosion.

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

HOT PARTS can cause burns and injury.

 Do not touch hot compressor or air system

parts.

 Let system cool down before touching or ser-

vicing.

 Read Owner’s Manual before using or servic-

ing unit.

 Stop engine and release air pressure before

servicing.

 Use only genuine replacement parts from the

manufacturer.

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

 Do not install unit near flammables.

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

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

FALLING UNIT can cause injury.

 Use lifting eye to lift unit and properly installed

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

 Lift and support unit only with proper equipment

and correct procedures.

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

extend beyond opposite side of unit.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or

stopping engine.

 Do not let low voltage and frequency caused by

low engine speed damage electric motors.

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

where applicable.

FLYING SPARKS can cause injury.

WELDING WIRE can cause injury.

 Do not press gun trigger until instructed to do

so.

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

other people, or any metal when threading
welding wire.

OVERUSE can cause OVERHEATING.

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

starting to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

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

according to instructions supplied with trailer.

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

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

 Sparks can cause fires — keep flammables away.

MOVING PARTS can cause injury.

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

rolls.

OM-225 590 Page 4

READ INSTRUCTIONS.

 Read Owner’s Manual before using or servic-

ing unit.

 Use only genuine replacement parts from the

manufacturer.

 Perform engine and air compressor mainte-

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

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

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

navigation, safety services, computers, and
communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

 The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the
installation.

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

equipment at once.

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

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

1-6. California Proposition 65 Warnings

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

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

 Electromagnetic energy can interfere with

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

 Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

 Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

 Be sure this welding machine is installed and grounded

according to this manual.

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

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

For Gasoline Engines:

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

For Diesel Engines:

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

1-7. Principal Safety Standards

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

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

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

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

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

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

1-8. EMF Information

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

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

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

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

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

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

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

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

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

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

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

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

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

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

About Implanted Medical Devices:

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

OM-225 590 Page 5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_2007−04fre

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

2-1. Signification des symboles

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

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

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

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

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

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

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

UN CHOC ÉLECTRIQUE peut tuer.

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

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

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

tant pas de trous.

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

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

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

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

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

MENT si le procédé de soudage le demande.

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

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

 Des précautions de sécurité supplémentaires sont requises dans

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

OM-225 590 Page 6

 Indique des instructions spécifiques.

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

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

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

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

1910.147 (voir normes de sécurité).

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

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

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

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

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

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

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

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

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

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

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

sante ou mal épissés.

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

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

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

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

 Ne pas toucher des porte électrodes connectés à deux machines

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

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

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

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

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

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

contact avec tout objet métallique.

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

 Couper l’alimentation du poste et décharger les condensateurs

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

DES PIÈCES CHAUDES peuvent

-

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e

s

u

e

n

o
e

e

e

u
n

e

f

e

c

e

provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

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

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

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

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

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

facial.

LES FUMÉES ET LES GAZ peuvent êtr
dangereux.

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

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

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

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

approuvé.

 Lire et comprendre les spécifications de sécurité des matériaux

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

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

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

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

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

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

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

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

 Fermer l’alimentation du gaz protecteur en cas d

non utilisation.

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

respirateur d’adduction d’air homologué.

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

Le rayonnement de l’arc du procédé de soudag

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

 Porter un casque de soudage approuvé muni de verres filtrants

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

 Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

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

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

 Porter des vêtements confectionnés avec des matières résistan-

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

LE SOUDAGE peut provoquer un in
cendie ou une explosion.

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

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

 Déplacer toutes les substances inflammables à une distance de

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

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

sur des substances inflammables.

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

de métal chaud.

 Des étincelles et des matériaux chauds du soudage peuvent

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

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

proximité.

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

peut déclencher un incendie de l’autre côté.

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

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

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

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

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

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

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

lées.

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

électrode ou couper le fil à la pointe de contact.

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

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

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

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

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

ce d’étincelles incandescentes ni de flammes.

 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

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

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

LE BRUIT peut affecter l’ouïe.

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

 Porter des protections approuvés pour les or

les si le niveau sonore est trop élevé.

OM-225 590 Page 7

LES CHAMPS MAGNETIQUES peuv-

a

a

a
n

e

s
s

o

e

s

e

t

o

,

-

e

­r

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

ent affecter des implants médicaux.

 Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

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

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

 Tenir les bouteilles éloignées des circuits de soudage ou autres

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

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

Si des BOUTEILLES sont endomm
gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du g

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

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

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

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

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

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

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

2-3. Dangers existant en relation avec le moteur

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

circuits électriques.

une bouteille.

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

bouteille.

d’utilisation ou de branchement de la bouteille.

samment de personnes pour soulever et déplacer les bouteilles.

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

L’EXPLOSION DE LA BATTERIE peu
RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gant

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

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

de batterie.

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

la batterie.

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

des véhicules de démarrage rapide.

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

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

dernier lieu.

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

 Arrêter le moteur avant de vérifier le niveau d

carburant ou de faire le plein.

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

ou d’une flamme nue.

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

pour son expansion.

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

carburant renversé avant de faire démarrer le moteur.

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

remplissage.

DES ORGANES MOBILES peuvent pr
voquer des blessures.

 Ne pas approcher les mains des ventilateurs

courroies et autres pièces en mouvement.

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

couvrements et dispositifs de protection.

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

OM-225 590 Page 8

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

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

 Pour empêcher tout démarrage accidentel pendant les travaux

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

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

des organes mobiles.

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

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

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

mise en route accidentelle du moteur.

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

tion sur le générateur.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

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

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

 Il est préférable de vérifier le liquide de refroi-

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

 Toujours vérifier le niveau de liquide de refroidissement dans le

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

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

me suivant.

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

le bouchon du radiateur.

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

avant d’enlever le bouchon.

L’utilisation d’un groupe autonome

t
,

e

-

e

s

r

u

à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.

 Les fumées d’un groupe autonome contient du

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

 JAMAIS utiliser dans une maison ou garage,

même avec les portes et fenêtres ouvertes.

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

bouches aération.

LA CHALEUR DU MOTEUR peut pro­voquer un incendie.

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

proximité de surfaces inflammables.

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

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

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

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

2-4. Dangers liés à l’air comprimé

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

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

page, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer
des blessures.

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

soi-même.

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

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

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

LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du

moteur de provoquer un incendie.

 Utiliser uniquement un pare-étincelles

approuvé − voir codes en vigueur.

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

 Ne pas couper ou gouger à proximité de pro-

duits inflammables.

 Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provo­quer des brûlures et blessures.

 Ne pas toucher le compresseur ou d’autres

éléments du circuit air comprimé chauds.

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

maintenance.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 Arrêter le moteur et relâcher la pression avant

d’effectuer la maintenance.

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

constructeur.

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

Risque D’INCENDIE OU D’EXPLO­SION.

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

à proximité de surfaces inflammables.

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

duits inflammables.

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

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

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

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

LA CHUTE DE L’APPAREIL peut blesser.

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

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

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

l’équipement approprié et en suivant le
procédures adéquates.

OM-225 590 Page 9

LE SURCHAUFFEMENT peut endom-

e

-

-

,

t

a

-

n

u

-

mager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant d

démarrer ou d’arrêter le moteur.

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

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

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

s’il y a lieu.

LES ÉTINCELLES VOLANTES ris­quent de provoquer des blessures.

 Porter un écran facial pour protéger le visage e

les yeux.

 Affûter l’électrode au tungstène uniquement à l

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

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

stance inflammable.

DES ORGANES MOBILES peuvent
provoquer des blessures.

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

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

 Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

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

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

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter le fac-

teur de marche nominal.

 Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

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

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les
circuits imprimés.

 Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques pour stocker,

déplacer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut
entraîner des blessures.

 Utiliser les supports de la remorque ou des

blocs pour soutenir le poids.

 Installer convenablement le poste sur la remor-

que comme indiqué dans le manuel s’y rappor­tant.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

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

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

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

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

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

 Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’instal­lation.

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

cien qualifié les interférences résultant de l’installation.

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

pareil.

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

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

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

 L’énergie électromagnétique risque de provo-

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

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

compatible électromagnétiquement.

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

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

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

ment électronique sensible.

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

conformément à ce mode d’emploi.

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

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

OM-225 590 Page 10

2-6. Proposition californienne 65 Avertissements

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

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

2-7. Principales normes de sécurité

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

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

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

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

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

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

Pour les moteurs à essence :

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

Pour les moteurs diesel :

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

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

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

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

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

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

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

2-8. Information EMF

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

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

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

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

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

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

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

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

En ce qui concerne les implants médicaux :

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

OM-225 590 Page 11

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 Protector Engine Oil

A

Check Injectors/

Pump

Positive Negative

Amperes

Check Valve

Clearance

Certified/Trained

Volts Panel/Local Remote

V

On Temperature Output (Contactor)

Stick (SMAW)

Welding

Time

h

TIG (GTAW)

Welding

Hours

Read Operator’s

Manual

MIG (GMAW)

s

Fuel

Mechanic

Welding

Seconds

3

1

Protective Earth

(Ground)

Welding Arc

Alternating

Current

Three Phase

Single Phase

OM-225 590 Page 12

SECTION 4 − SPECIFICATIONS

120/240 V AC

Air Cooled,

22.3 gal
Dual

Volts DC, 40%

(/ y

Engine

L

g

Engine End

! Do not exceed tilt angles or engine could

could tip

C

D

E

F

20

J

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

1

(Right Side)

2

(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)

L

21/32 in (17 mm) Dia.

16 Holes

Weight

2115 lb (959 kg)

Lifting Eye Weight Rating:

2161 lb (980 kg) Maximum

L

G

K

J

H

158 699

Generator Power

Single-Phase,

4 kVA/kW, 34/17 A,

120/240 V AC,

(4 kVA/kW Shared By

All Receptacles)

A

C

B

Rating

,

50/60 Hz

Engine

Deutz F3L-914

Air-Cooled,

Three-Cylinder,

48.2 HP Diesel
Engine

! Do not exceed tilt an

be damaged or unit could tip.

les or engine could

Fuel

Capacity

(84.4 L)

! Do not move or operate unit where it

could tip.

20°
20°

.

°

17.5°

17.5°

angles_1 8/99

OM-225 590 Page 13

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

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

U.S. GAL./HR.

CC

CV

DC WELD AMPERES AT 40% DUTY CYCLE

4-5. AC Generator Power

300

150

250

125

200

100

150

75

AC VOLTS

100

50

50

25

0

0

0 5 10 15 20 25 30

AC AMPERES IN 240V MODE

195 711

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

OM-225 590 Page 14

0102030405060

AC AMPERES IN 120V MODE

193 018

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.

NOTICE − 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

0

Minutes

15

A or V

OR

Reduce Duty Cycle

Ref. rduty1 5/95 − 194 313-A

OM-225 590 Page 15

4-7. Volt-Ampere Curves

A. CC/DC − Single Mode

100

80

DC VOLTS

60

40

MIN MED MAX

20

0

0 100 200 300 400 500 600 700 800 900 1000

B. CC/DC − Dual Mode

100

80

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

60

40

DC VOLTS

20

0

0 50 100 150 200 250 300 350 400 450 500

C. CV/DC Mode

100

80

60

DC VOLTS

40

20

MAX
MED

MIN

MAXMEDMIN

DC AMPERES

0

0 100 200 300 400 500 600 700 800 900 1000

OM-225 590 Page 16

DC AMPERES

194 397 / 194 398 / 194 399

SECTION 5 − INSTALLATION

 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

! Always securely fasten welding

generator onto transport vehicle
or trailer and comply with all DOT

Movement

Location / Airflow Clearance

! Do not lift unit from end.

OR

OR

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.

NOTICE − Do not install unit where air
flow is restricted or engine may over­heat.

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.

18 in

(460 mm)

18 in

(460 mm)

Grounding

GND/PE

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

2

3

! Bed liners, shipping skids, and some running

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

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

4

install1 8/06 − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / 804 712

OM-225 590 Page 17

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

3

2

1

4

! Always wear a face shield,

rubber gloves and protective
clothing when working on a
battery.

Remove battery from unit.
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

OR

+

! Connect (−) Cable Last.

+

−

drybatt1 6/05 − S-0886

−

Tools Needed:

OM-225 590 Page 18

1/2 in

Ref 225 543 / 153 654-C

5-4. Installing Exhaust Pipe

Tools Needed:

1/2 in

5-5. Engine Prestart Checks

1/2 in

(13 mm)

OFF

Full

Diesel

FUEL ON

! 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

NOTICE − Do not use gasoline.
Gasoline 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. Use primer pump to
prime injector system (see Section
8-7).

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.

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 804 285 / 013 466

OM-225 590 Page 19

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.

OM-225 590 Page 20

5-7. Weld Output Terminals

Welder A (Left) Side

7

4

Do not place

anything between

weld cable terminal

and copper bar.

Welder B (Right) Side

123

123

Tools Needed:

3/4 in

5

6

! Stop engine.

1 Negative (−) Weld Output Terminal
2 CV Weld Output Terminal
3 CC Weld Output Terminal

! Failure to properly connect weld

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

4 Weld Output Terminal

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

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

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

Ref. 225 543 / 802 292-A / 803 788-A

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
connections (CC only).

If unit has the Polarity switch option, the
Negative (−) weld output terminals are la-
beled Work receptacles and the CC weld
output terminals are labeled Electrode re­ceptacles.

OM-225 590 Page 21

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

2

Note position

of Process

Selector

switches.

1

Welder B (Right) Side

2

! Stop engine.

NOTICE − 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

OM-225 590 Page 22

3

Route cables through strain reliefs.
2 Electrode Holder Cables
3 Work Cables
For Stick/TIG welding Direct Current Elec-

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

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

Ref. 225 543 / 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.

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

terminals, 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

2

Welder B (Right) Side

Note position

of Process

Selector

switches.

1

4

2

3

Ref. 225 543 / 802 292-A

! Stop engine.

NOTICE − 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 Elec-

trode 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-225 590 Page 23

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

2

Polarity

switch.

1

Welder B (Right) Side

Note position

of optional Po-

larity switch.

2

! Stop engine.

NOTICE − 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-225 590 Page 24

3

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. 225 543 / 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.

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.

 When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−)

weld terminals, 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).

Welder A (Left) Side

Direct Current Electrode Positive
(DCEP) connections are shown.

Note position

of Process

Selector

switches.

Welder B (Right) Side

3/4 in

Note position

of optional

Polarity

switch.

2

! Stop engine.

NOTICE − 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

1

3

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.

Note position of optional

4

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.

Polarity switch.

2

Ref. 225 543 / 802 292-A

 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-225 590 Page 25

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

3

Polarity

switch.

! Stop engine.

NOTICE − 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 Electrode Holder Cable
3 Wire Feeder Cable
4 Work Cables
For Stick/TIG welding Direct Current Elec-

trode Positive (DCEP), connect work

1

4

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.

2

Ref. 225 543 / 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-225 590 Page 26

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.

 When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−)

weld terminals, 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).

Welder A (Left) Side

Note position of
optional Polarity

switch.

3

Direct Current Electrode Positive
(DCEP) connections are shown.

Note position

of Process

Selector

switches.

1

4

Welder B (Right) Side

5

2

! Stop engine.

NOTICE − 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. 225 543 / 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-225 590 Page 27

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.

1

3

Welder B(Right) Side

2

Tools Needed:

3/4 in

! Stop engine.

NOTICE − 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-225 590 Page 28

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

Ref. 225 543 / 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.

Notes

OM-225 590 Page 29

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-225 590 Page 30

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

1

2

3

4

5

6

! 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.

ether1 7/96 − 153 382-A / 225 543 / 804 289-A

5-17. Remote 14 Receptacle Information

 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

24 VOLTS AC

REMOTE

OUTPUT

CONTROL

A/V

AMPERAGE

VOLTAGE

A 24 volts ac. Protected by supplementary protectors 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.

F

H

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

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

115 VOLTS AC

GND

*The remaining sockets are not used.

I

J

K Chassis common.

G Circuit common for 24 and 115 volts ac circuits.

115 volts, 15 amperes, 60 Hz ac. Protected by supplementary protectors CB5 and
CB6.

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

OM-225 590 Page 31

5-18. Remote 14 Receptacle Connections

AJ

K

B

L

C

D

I

NH

M

G

F

E

AJ

K

B

L

NH

C

M

D

E

OR

Dual Operator Operation

I

G

F

OR

AJ

K

B

L

NH

C

M

D

E

OR

Single Operator Operation

I

G

600 AMPS

F

OM-225 590 Page 32

804 289-A / Ref 225 543

SECTION 6 − OPERATING THE WELDING GENERATOR

 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.

6-1. Engine Controls

3

1

45

2

 See Section 6-3 for weld control

descriptions.

1 Engine Start Button
2 Stop Switch
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.

225 543 / 804 289-A

To Stop: Push switch down and hold. Re­lease when engine stops.

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

NOTICE − If light goes on, stop engine and
check alternator and engine belt.

5 Engine Hour Meter

OM-225 590 Page 33

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

1

300 AMPS 300 AMPS

WELDER A Welder B

600 AMPS

Welder B

600 AMPS

10

342

89

5

7

6

OM-225 590 Page 34

Ref. 225 543 / 191 848 / 804 289-A

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.

NOTICE − Do not switch under load or with
output 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)

NOTICE − 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-225 590 Page 35

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. 120 Volt And 240 Volt Duplex Receptacles

64

! 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

3

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 Supplementary Protectors CB1 And

CB2

6 Supplementary Protectors 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.

CB3 and CB4 protect RC2 and GFCI 2 from
overload. If CB3 or CB4 opens, RC2 does

152

190 376

not work. 120 volts may still be present at
RC2. If CB4 opens, GFCI 2 does not work.
Press button to reset.

 If a supplementary protector 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-225 590 Page 36

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

! Stop engine before maintaining.

Recycle engine

fluids.

 See Engine Manual and Maintenance Label

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

Every

8

Hours

Every

50

Hours

Every

100

Hours

Every

250

Hours

Every

500

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

1/2 in.

(13 mm)

 Unreadable Labels Spark Arrestor  Alternator Belt Tension

Reference

Section 5-5,
8-4

Section 8-3

Engine
Manual,
Section 8-8

Every

1000

Hours

 Weld Cables  Oil  Oil Filter

OR

Valve Clearance*  Inside Unit  FuelFilter  Drain Sludge

 Slip Rings*
 Brushes*

FUEL

SLUDGE

Section 8-4,
8-9 and En­gine Manual

OM-225 590 Page 37

8-2. Maintenance Label

OM-225 590 Page 38

8-3. Servicing Air Cleaner

Keep nozzle
2 in (51 mm)

from element.

Blow Inspect

Optional

! Stop engine.

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

2

41 3

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

 The air cleaner primary element can

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

5

to clean or replace the primary ele­ment.

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

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

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

To clean air filter:

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

NOTICE − Do not clean housing with air
hose.

Clean primary element with compressed
air only.

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

Reinstall primary element and cap (dust
ejector down).

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

OM-225 590 Page 39

8-4. Servicing Fuel And Lubrication Systems

8

Under Left Side

Of Fuel Tank Behind

Control Panel

2

OFF

! Stop engine and let cool.

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

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

To change oil and filter:

See engine manual.

6

3

1

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. Use
primer pump to prime injector sys­tem (see Section 8-7).

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:

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

OM-225 590 Page 40

FUEL ON

7

4

5

225 543 / 804 285-A / 013 466

8-5. Adjusting Engine Speed

Engine Speed

(No Load)

Weld/Power

1

2

Engine speed is factory set and
should not require adjustment. Af-

RPM (HZ)

1850 (61.6)

2

3

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

1 Adjustment Rod
2 Thumbwheels
Start engine and turn thumbwheels

to increase or decrease engine no
load speed.

3 Speed Control Lever
Rotating lever clockwise increases

engine speed.

! Stop engine.

Close side door.

Tools Needed:

3/8 in

8-6. Servicing Optional Ether Starting Aid

3

804 285-A

! 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

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

2

ether2 7/96 − 153 382-A / Ref. 225 543 / S-0692

OM-225 590 Page 41

8-7. Priming Fuel System

! Stop engine.

Open right hand side door.
1 Primer Pump
After running out of fuel or changing

fuel filters, use pump to prime fuel
system.

Push primer pump approximately
12 times to pump fuel into the injec­tor system. Use Engine Control
switch to start engine.

1

225 543 / 804 286-A

OM-225 590 Page 42

8-8. Inspecting And Cleaning Optional Spark Arrestor Muffler

3

2

1

! 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

8-9. Checking Generator Brushes

1/2 in (13 mm)

Minimum Length

Replace

Damaged

Brushes

1-1/8 in (28.6 mm)

New Length

1

Ref. 800 633-B / Ref. 225 543

! 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 225 543 / S−0233−A

OM-225 590 Page 43

8-10. Circuit Protection

1

2

Tools Needed:

3

4

7

8

5

! Stop engine.

 When a supplmentary protector 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.

9

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

5 Supplementary Protector CB5
6 Supplementary Protector CB6
7 Supplementary Protector CB7
8 Supplementary Protector CB8
Supplementary Protector 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.

Supplementary Protector 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.

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

Supplementary Protector CB8 protects the
generator field flashing circuit. If CB8

6

Ref. 802 300 / Ref. 802 292-A

opens, weld and 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 supplementary pro­tector.

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.

OM-225 590 Page 44

8-11. 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 8-10).

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 8-10). 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 8-10).

Reset supplementary protectors CB7 and/or CB8 (see Section 8-10).

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 8-10).

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 8-10).

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.

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

Check fuse F4, and replace if open (see Section 8-10).

Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP4 to
reset (see Section 8-10).

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.

OM-225 590 Page 45

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 8-10).

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 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 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.

OM-225 590 Page 46

B. Generator Power

Trouble Remedy

No output at generator power ac recep­tacles.

High or low output at generator power ac
receptacles.

Reset receptacle supplementary protectors (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 8-10).

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.

Circuit breaker CB12 may have tripped. CB12 automatically resets when fault is corrected. Have Factory
Authorized Service Agent check wiring harness and components.

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 engine charging system according to en­gine manual.

Have Factory Authorized Service Agent check time delay relay TD1, control relay CR5, fuel pump, and
fuel solenoid FS1.

Air in fuel system. Use primer pump to prime fuel system (see Section 8-7).

See engine manual.

Engine suddenly stops. Check oil level (see Section 5-5). Automatic shutdown system stops engine if oil pressure is too low or

Engine slowly stopped and cannot be re­started.

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

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.

oil temperature is too high. Automatic shutdown system is inhibited for 30 seconds after start−up.

See engine manual.

Check fuel level (see Section 5-5).

Check engine air and fuel filters (see Sections 8-3 and 8-4).

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

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

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

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator and connections according to engine manual.

Dry engine (see Section 10).

OM-225 590 Page 47

SECTION 9 − ELECTRICAL DIAGRAMS

OM-225 590 Page 48

Figure 9-1. Circuit Diagram For Welding Generator

225 565-C

OM-225 590 Page 49

10-1. Wetstacking

1

SECTION 10 − RUN-IN PROCEDURE

! Do not perform run-in

2

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 2007−05

OM-225 590 Page 50

10-2. Run-In Procedure Using Load Bank

4

2

3

! Stop engine.
! Do not touch hot exhaust

pipe, engine parts, or load
bank/grid.

! Keep exhaust and pipe away

from flammables.

! Do not perform run-in

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

1 Load Bank

1

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.

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

! Stop engine and let cool.

4 Engine Exhaust Pipe
Repeat procedure if wetstacking is

present.

S-0683

OM-225 590 Page 51

10-3. Run-In Procedure Using Resistance Grid

6

2

3

4

+

5

! Stop engine.
! Do not touch hot exhaust

pipe, engine parts, or load
bank/grid.

! Keep exhaust and pipe away

from flammables.

! Do not perform run-in

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

1 Resistance Grid
Use grid sized for generator rated

output.

1

Turn Off grid.
2 Welding Generator

Place 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.

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

! Stop engine and let cool.

6 Engine Exhaust Pipe
Repeat procedure if wetstacking is

present.

OM-225 590 Page 52

S-0684

SECTION 11 − GENERATOR POWER GUIDELINES

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

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

 Be sure equipment has double

1

2

3

OR

insulated symbol and/or word­ing on it.

! Do not use 2-prong plug un-

less equipment is double in­sulated.

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

11-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

2

3

! Always ground generator

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

! Also see AWS Safety &

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

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied)
3 Metal Vehicle Frame
Connect cable from equipment

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

 Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

! Bed liners, shipping skids,

and some running gear insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equip-

ment grounding terminal to

bare metal on the vehicle

frame as shown.

! If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

S-0854

OM-225 590 Page 53

11-3. Grounding When Supplying Building Systems

1 2

GND/PE

2

3

1 Equipment Grounding

Terminal
2 Grounding Cable
Use #10 AWG or larger insulated

copper wire.
3 Ground Device

 Use ground device as stated in

electrical codes.

! Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

! Also see AWS Safety &

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

11-4. How Much Power Does Equipment Require?

3

2

1

3

VOLTS 115
AMPS
Hz

4.5
60

ST-800 576-B

1 Resistive Load
A light bulb is a resistive load and

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

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

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

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

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

watts.
Example 2: If three 200 watt flood

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

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

flood lamps and drill is 1120 watts.

OM-225 590 Page 54

S-0623

11-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

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

Capacitor Start-Induction Run 1/3 HP 2020 720

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

1 HP 6100 1600

1-1/2 HP 8200 2200

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

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

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

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

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

Farm/Home Equipment Rating Starting Watts Running Watts

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

1-1/2 HP 8200 2200

2 HP 10550 2850
3 HP 15900 3900

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

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

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

OM-225 590 Page 55

11-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

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

Circular Saw 6-1/2 in 500 500

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

Table Saw 9 in 4500 1500

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

8 in 3900 1400

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

1 HP 6000 1500

1-1/2 HP 8200 2200

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

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

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

Metal Halide 313 250

Mercury 1000

Sodium 1400

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

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

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

2-1/2 HP 1300 1300

OM-225 590 Page 56

11-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

Motor Start

Code

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

G H J K L M N P

1 Motor Start Code
2 Running Amperage

4
1

VOLTS AMPS

3

CODE 60

HP

AC MOTOR

230 2.5

M

1/4

Hz
PHASE

1

2

3 Motor HP
4 Motor Voltage
To find starting amperage:

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

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

age (see example).
Welding generator amperage out-

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

(kVA/HP x HP x 1000) / Volts =

Starting Amperage

Example: Calculate starting amper­age required for a 230 V, 1/4 HP mo­tor with a motor start code of M.

Volts = 230, HP = 1/4, kVA/HP =

11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2

amperes.

S-0624

11-9. How Much Power Can Generator Supply?

1

2

1 Limit Load To 90% Of

Generator Output

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

2 5 Second Rule
If motor does not start within 5

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

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

OM-225 590 Page 57

11-10. Typical Connections To Supply Standby Power

123

Utility

Electrical

Service

Transfer Switch

5

Essential

Loads

Fused

Disconnect

Switch

(If Required)

4

Welding

Generator

Output

! Have only qualified persons

perform these connections
according to all applicable
codes and safety practices.

! Properly install and ground

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

 Customer-supplied equipment

is required if generator will sup­ply standby power during
emergencies or power out­ages.

1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load

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

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

3 Fused Disconnect Switch
Install correct switch (customer-

supplied) if required by electrical
code.

4 Welding Generator Output
Generator output voltage and wir-

ing must be consistent with regular
(utility) system voltage and wiring.

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

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

5 Essential Loads
Generator output may not meet the

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

OM-225 590 Page 58

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

Load (Watts) 4 6 8 10 12 14

If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

Current

(Amperes)

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

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

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

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

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

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

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

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

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

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

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

*Conductor size is based on maximum 2% voltage drop

Load (Watts) 4 6 8 10 12 14

OM-225 590 Page 59

 Hardware is common and

not available unless listed.

SECTION 12 − PARTS LIST

26

25

27

94−See Fig. 12-2

93

92

96

95

97

15

16

83

17

82

24

18

19

20

29

21

31

28

30−See Fig. 12-4

22

23

32

10

9

35

81

33

34

36

37

38

39

40

41

5

6

7

10

13

11
12

9

8

9

10

14

84

4

3

2

1

101

100

99

98

OM-225 590 Page 60

91

90

89

88

87

85

86

Figure 12−1. Main Assembly

53

42

43

102

45−See Fig. 12-3

44

48

47

46

49

50

51

52

54

55

56

57

49

58

62

80

79

76−See Fig. 12-5

78

38

37

77

75

40

39

59

74

73

72

60

71

70

61

66

69

68

67

63

64

65

804 287-A

OM-225 590 Page 61

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

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 (includes) 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 010 314 VALVE, shut-off fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 039 599 FITTING, brs barbed M 5/16 tbg x 1/4 NPT 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

19 216 565 BRACKET, mounting components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 TD1 214 928 TIMER, delay on make/break open 30 sec 12vdc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 SR4, SR5 035 704 RECTIFIER, Integ bridge 40. amp 800v 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 CR5 090 104 RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 CB12 205 927 CIRCUIT BREAKER, auto reset 12vdc 12 amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 108 081 TERMINAL PROTECTOR, battery post mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 124 941 CABLE, bat pos 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 208 353 HOLD DOWN, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 032 453 CABLE, bat neg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 190 896 BATTERY, stor 12v 660 crk 110 rsv gp 24 low 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 010 460 STUD, stl .312-18 x 10.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 SR2, SR3Figure 12−5. RECTIFIER ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 013 466 LABEL, fuel shut-off 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 145 282 FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 202 242 BASE, fuel filter assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 192 744 FILTER, fuel spin−on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 135 205 NUT, 625-11 .94 hex .76H stl pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 116 707 SUPPORT, front engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 119 849 SCREW, 625-11 x 4.00 hexhd pln gr 5 pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 071 731 WASHER, flat stl .656 ID x 2.250 OD x .187thk 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 071 890 RETAINER, mount eng/gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 071 730 TUBING, stl .875 OD x 12ga wall x 2.500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 072 848 MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 50 dur 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 010 875 CLAMP, muffler 2.000 dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 105 734 PIPE, muffler extension elbow 1.875 OD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 176 232 BAFFLE, air muffler exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 Figure 12−3. SIDE CONTROL PANELS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 +105 909 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 192 041 LABEL, use diesel fuel only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 035 968 WASHER, flat rbr 3.625 ID x 5.875 OD x .062thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 158 610 LABEL, warning electric shock 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 168 385 LABEL, warning battery explosion 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 +192 313 DOOR, side LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 222 513 LABEL, warning falling equipment can cause serious 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 117 257 PANEL, end engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 +192 314 DOOR, side RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 225 589 LABEL, diesel engine maintenance f−3l914 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 004 130 BRACKET, support door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-225 590 Page 62

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12−1. Main Assembly (Continued)

57 087 341 BUMPER, door 1.000 OD x .750 high 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 087 336 LATCH 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 048 213 BAFFLE, air intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

194 467 WASHER, flat (for baffle) 6.25 ID x 11.50 OD x .62 T buna 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 023 313 CLAMP, hose 3.250-3.000 clp dia slftg 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 225 643 TUBE, air intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 225 642 HOSE, air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 189 764 AIR CLEANER, intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 165 785 HOSE, air cleaner 2.500 id 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

65 203 462 BRACKET, mtg air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 223 249 ENGINE, Deutz dsl elec F3L914 (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*064 677 FILTER, oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*064 686 FILTER, fuel secondary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*066 271 V−BELT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 507 HOSE ASSY, oil drain 20.000 lg (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 165 271 VALVE, oil drain 3/8−18 nptf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 176 529 FTG, hose brs barbed fem 1/2 tbg x 3/8 npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 113 854 HOSE, sae .500 id x .780 od xcoil 1.66ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

70 176 528 FTG, hose brs barbed elbow m 1/2 tbg x 1/2 npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 206 906 ADAPTER, oil drain fitting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 047 235 WASHER, seal oil copper .879id x 1.059od 111−8737 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 195 746 SENDER, coolant temp & 130c switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 195 745 SWITCH, pressure oil 1.5 bar nc cont 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 083 476 MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 60 dur 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 Figure 12−4. GENERATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 225 120 LABEL, warning moving parts can cause injury 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 176 236 BAFFLE, air outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 CLAMP, muffler (included with engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 105 733 PIPE, muffler extension elbow 1.875 OD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 165 739 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 191 446 EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) 2.1ft. . . . . . . . . . . . . . . . . . . . . . . .

83 173 352 EXTRUSION, rubber clamp/bulb (order by ft) 2.4ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 192 305 TRAY, base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 176 167 NUT, 250-20 acorn nylon 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 192 303 ANGLE, mtg stabilizer 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 Z1, Z2 192 296 STABILIZER 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 205 791 BRACKET, mtg fuse assembly (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 204 965 STRIP, insulation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 026947 STAND-OFF, insul .250-20 x 1.0 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91 F11-13, F21-23 027 267 FUSE, link 300 A 250 volt 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 192 304 PANEL, front lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 233 953 LABEL, warning general precautionary CSA 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 Figure 12−2. FRONT PANEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 175 256 INSULATOR, side RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96 192 300 SHROUD, generator LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 T2, T4 192 371 TRANSFORMER, 115V pri 24VCT 8A w/leads 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98 192 301 SHROUD, generator RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 168 829 TRANSDUCER, current 1000A module max open loop 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 192 299 SHROUD, generator center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 194 021 CAPACITOR ASSEMBLY, (includes) 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-225 590 Page 63

Item

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Mkgs.

Part

No.

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Quantity

Figure 12−1. Main Assembly (Continued)

102 233 088 LABEL, danger using a generator indoors can kill you in minutes (unit) 1. . . . . . . . . . . . . . . . . .

193 501 KIT, label (includes safety and informational labels) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

individually or as part of Label Kit 193 501

*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.

6

5
4

3

2

1

42

41

40

36

39

38

37

31

35

7

8

9

29

30

31

32

26

10

27

28

22

25

12

11

24

18

12

23

21

13

22

21

20

14

19

15

16

13

17

18

OM-225 590 Page 64

34

33

804 290-A

Figure 12−2. Front Panel

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12−2. Front Panel (Figure 12−1. Item 94)

1 225 550 PANEL, front control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 209 056 COVER, receptacle w/gasket 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 206 795 BOOT, circuit breaker 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 PLATE, ident control rating (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 190 375 NAMEPLATE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 216 270 PANEL, aux power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 GFCI1,2 151 981 RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI 2. . . . . . . . . . . . . . . . . . . . . . . . .

8 CB1-4 093 996 SUPPLEMENTARY PRO, 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 SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac 2. . . . . . . . . . . . . . . . . . .

206 795 BOOT, circuit breaker clear hex nut 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 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

29 S2 192 292 SWITCH, paralleling 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 S4 ♦021 467 SWITCH, tgl spst 3a 250v off−none−(on) spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦021 385 BOOT, toggle switch lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 PB1 046 433 SWITCH, pb mc no spst 35a 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 S14 199 691 SWITCH,tgl spdt 6a 125vac on−none−mc spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 083 030 STUD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 HM 210 424 METER, hour 12-24VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 021 385 BOOT, toggle switch lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 PL1 188 266 LIGHT, ind red lens 13V (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 082 788 HOLDER, light ind only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 048 155 BULB, incand min 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 082 789 LENS, light ind red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 010 647 PIN, spring CS .156 x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 111 785 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 PLATE, ident control rating (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.
♦OPTIONAL

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

OM-225 590 Page 65

29

30

31

 Hardware is common and

not available unless listed.

1

32

26

27

25

28

24

23

22

2

3

4

33

34

7

8

21

20

6

9

10

19

18

11

16

17

15

14

13

35

36

5

12

OM-225 590 Page 66

802 320-A

Figure 12−3. Side Control Panels − Welder B (Right) Side Shown

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12−3. Side Control Panels (Figure 12−1. Item 45)

1 +192 330 PANEL, side output RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 (includes) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

163 557 SWITCH, mode single 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202 881 COVER, dust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 159 863 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CR2, CR3 000 770 RELAY, encl 24VDC 3PDT 10A/120VAC 11 pin 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 GRD 185 011 STUD, primary board brs 10-32 x 1.592 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10S3,6,7,8,10,11 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 R1,2,7,8 035 897 POTENTIOMETER, cp std slot 1t 2w 1k linear 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 LS1,2,3,4 089 645 SWITCH, lim 11A 125V 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 PC2, PC6 226 095 CIRCUIT CARD ASSEMBLY, display w/program 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 165 316 STAND-OFF, No. 6-32 x .875 lg .312 hex nyl 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 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 039 047 TERMINAL, pwr output red (includes) 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 039 046 TERMINAL, pwr output black (includes) 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 3T, 4T 190 210 BLOCK, term 5-3-3 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 CB5, CB6 139 266 SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac 2. . . . . . . . . . . . . . . .

30 RC8, RC9 134 735 CONNECTOR, circ MS/CPC 14skt 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 PC3, PC7 181 261 CIRCUIT CARD ASSEMBLY, filter 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 165 316 STAND-OFF, No. 6-32 x .875 lg .312 hex nyl 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 ♦059 773 HANDLE, switch 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 ♦010 647 PIN, spring 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦091 067 SWITCH, polarity 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦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. Order label

individually or as part of Label Kit 193 501

♦OPTIONAL

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

OM-225 590 Page 67

 Hardware is common and

not available unless listed.

2

4

3

8

10

9

6

7

11

1

5

12

13

15

14

Figure 12−4. Generator

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12−4. Generator (Figure 12−1. Item 76)

1 *151 299 BRUSH, contact elect clrg .375 x .750 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 188 387 BRUSHHOLDER/BRACKET ASSEMBLY, (includes) 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 (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 039 207 BAFFLE, air generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 192 286 ROTOR, generator (includes) 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 195 704 STATOR, exciter aux pwr 120/240 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 173 068 ENDBELL, generator (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 143 220 O-RING 2.859ID x .139CS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ref. 048 456-E

Quantity

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

individually or as part of Label Kit 193 501

*Recommended Spare Parts.

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

OM-225 590 Page 68

1

Figure 12−5. Rectifier Assembly

 Hardware is common and

not available unless listed.

802 319

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12−5. Rectifier (Figure 12−1. Item 30)

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

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.

 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase

components separately or as part of the associated wiring harness.

Item

No.

Dia.

Mkgs.

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

CR3 000 770 RELAY, encl 24VDC 3PDT 10A/120VAC 11 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GRD 185 011 STUD, primary board brs 10-32 x 1.592 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S8,10,11 011 609 SWITCH, tgl SPDT 15A 125VAC on-none-on 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R7,8 035 897 POTENTIOMETER, cp std slot 1t 2w 1k linear 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LS3, 4 089 645 SWITCH, lim 11A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG27 131 056 CONNECTOR, housing plug pins and sockets 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part

No.

Description

Quantity

Wiring Harnesses

195 702 HARNESS, wiring component panel (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188 512 SEAL, wire univ 6P/S 3 row 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 651 SEAL, wire univ 9P/S 3 row 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 218 HARNESS, wiring control box welder B (right) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 651 SEAL, wire univ 9P/S 3 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-225 590 Page 69

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Wiring Harnesses

192 208 HARNESS, wiring control box welder A (left) (includes) 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 336 HARNESS, wiring unit welder B (right) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4T 190 210 BLOCK, term 5-3-3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB6 139 266 SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac 1. . . . . . . . . . . . . . . . . . . . . . . .

RC9 134 735 CONNECTOR, circ MS/CPC 14skt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3T 190 210 BLOCK, term 5-3-3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB5 139 266 SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

225 595 HARNESS, engine du−op (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PB1 046 433 SWITCH, pb mc no spst 35a 12vdc w/black cap 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S14 199 691 SWITCH, tgl spdt 6a 125vac on−none−mc spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SR4,5 035 704 RECTIFIER, integ bridge 40. amp 800v 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 334 HARNESS, aux power panel (includes 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GFCI1,2 151 981 RCPT, str dx grd 2p3w 15/20a 125v *5−20r gfi 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC1,2 193 257 RCPT, str dx grd 2p3w 15/20a 250v *6−20r 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB1,2,3,4 093 996 SUPPLEMENTARY PRO, man reset 1p 20a 250vac frict 4. . . . . . . . . . . . . . . . . . . . . . . . .

OM-225 590 Page 70

Warranty Questions?

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

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you ...

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Support

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tough welding questions?
Contact your distributor.
The expertise of the
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there to help you, every
step of the way.

Effective January 1, 2007

(Equipment with a serial number preface of “LH” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the
engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches and Subarc (SAW) Guns

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

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

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

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

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.

miller_warr 2007−01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01