Miller Electric PipePro 304 User Manual

OM-492 190 603BF

2007−05

Processes

MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding

Flux Cored (FCAW) Welding

Stick (SMAW) Welding

TIG (GTAW) Welding

Air Carbon Arc (CAC-A)
Cutting and Gouging

Description

Engine Driven Welding Generator

™

PipePro 304

Visit our website at

www.MillerWelds.com

File: Engine-Driven

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. Symbol Definitions 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

4-2. Dimensions, Weights, and Operating Angles 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Duty Cycle And Overheating 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Volt-Ampere Curves 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Fuel Consumption 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

5-2. Engine Prestart Checks 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Adding Coolant To Radiator 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Connecting The Battery 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5-6. Connecting To Weld Output Terminals 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Selecting Weld Cable Sizes* 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Remote 14 Receptacle RC14 Information 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Guidelines For Installing Customer-Supplied Emergency Air Shutdown Valve 22 . . . . . . . . . . . . . . . . . . .

5-10. Operating Engine Block Heater 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

6-3. Meter Functions 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Mode Switch Settings 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Lift-Arc TIG Procedure 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Recommendations For Extreme Cold Weather Operation 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − OPERATING AUXILIARY EQUIPMENT 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Generator Power Receptacles And Circuit Breakers 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Optional GFCI Receptacles And Circuit Breakers 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Wiring Instructions For Optional 240 Volt, 3-Phase Twistlock Plug (NEMA L15-30P) 29 . . . . . . . . . . . . . .

7-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) 30 . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Maintenance Label 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Routine Maintenance 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Servicing Spark Arrestor 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Servicing Air Cleaner 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Servicing Engine Lubrication And Fuel Systems 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Servicing Engine Cooling System 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Replacing Throttle Solenoid TS1 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8. Adjusting Engine Speed 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9. Overload Protection 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10. Voltmeter/Ammeter Help Displays 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-11. Troubleshooting 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

OPTIONS AND ACCESSORIES
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-492 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-492 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-492 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-492 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-492 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-492 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

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e

n

o
e

e

e

u
n

e

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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-492 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-492 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-492 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-492 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-492 Page 11

3-1. Symbol Definitions

60% dut

99

A

10 − 34 V

100/50 A

13 gal (49 L)

Th

SECTION 3 − DEFINITIONS

Stop Engine

Start Engine Panel/Local Temperature Fuel

Engine Oil On

Engine

MIG (GMAW),

Wire

Foot Control Manual Control

Positive Negative

Fast

(Run, Weld/Power)

Read Operator’s

Manual

Stick (SMAW) TIG (GTAW) Circuit Protector

A

Fast/Slow
(Run/Idle)

Check Valve

Clearance

Amperes

Touch Start

(GTAW)

Alternating Current

(AC)

V

Slow (Idle)

Battery (Engine)

Volts

Pulsed

Output

Time

Hours

h

Do not switch while

welding

Wire Feed

14

SECTION 4 − SPECIFICATIONS

4-1. Weld, Power, And Engine Specifications

Welding

Mode

CC/DC

CV/DC

Rated

Welding

Output

300 A, 32 V,

Cycle

Maximum

Open-Circuit

Voltage

y

Remote 14

Receptacle

Electrode

Positive

Amperage

Range In
CC Mode

5 − 375

Voltage
Range In
CV Mode

s

Power Rating

Single-Phase,

120/240 V AC,

Seconds

Work Connection Glow Plug

Electrode Negative High Temperature

Generator

12 kVA/kW

,

60 Hz

Fuel Capacity Engine

13 gal (49 L)

Tank

Protective Earth

(Ground)

Kubota DH905

Water-Cooled,

-

ree-Cylinder,

Four-Cycle, 26 HP

Diesel Engine

OM-492 Page 12

4-2. Dimensions, Weights, and Operating Angles

C

gp

4 Hol

ti

20

Dimensions

Height 36 in (914 mm)

Width 24 in (610 mm)

Depth 59 in (1499 mm)

A 23-5/8 in (600 mm)

B 21-1/2 in (546 mm)

C 1 in (25 mm)

D 15-5/8 in (397 mm)

E 26-3/8 in (679 mm)

F 58-3/4 in (1492 mm)

G 13/32 in (10 mm) Dia.

Weight

925 lb (420 kg)

E

F

4-3. Duty Cycle And Overheating

C

D

A

B

Front Panel End

G

800 426

! Do not exceed tilt angles or engine could

be damaged or unit could tip.

! Do not move or operate unit where it could

es

p.

20°
20°

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

If unit overheats, output stops, a
Help message is displayed (see
Section 8-10), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.

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

20°

20°

Overheating

60% Duty Cycle

6 Minutes Welding 4 Minutes Resting

0

15

Minutes

Reduce Duty Cycle

A or V

OR

sduty1 5/95 / 196 698

OM-492 Page 13

4-4. Volt-Ampere Curves

A. CC Mode

Volt-ampere curves show mini­mum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall be­tween curves shown.

ARC CONTROL

B. CV Mode

OM-492 Page 14

178 652 / 178 653

4-5. Fuel Consumption

7.57

6.62

5.67

4.73

3.78

2.84

1.98

0.95

LITERS/HR.

2.00

1.75

1.50

1.25

1.00

0.75

0.50

0.25

0

U.S. GAL./HR.

3600 RPM

IDLE

0 50 100 150 200 250 300 350 400 450 500

DC WELD AMPERES AT 100% DUTY CYCLE

193 458

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-492 Page 15

SECTION 5 − INSTALLATION

5

-1. Installing Welding Generator

! Do not weld on base. Welding

on base can cause fuel tank fire
or explosion. Bolt unit down

Movement

! Do not lift unit from end.

OR

Location / Airflow Clearance

OR

(460 mm)

18 in

(460 mm)

Mounting

18 in

OR

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

using holes provided in base.

! Always securely fasten weld-

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

! Do not mount unit by support-

ing the base only at the four
mounting holes. Use cross­supports to adequately sup­port unit and prevent damage
to base.

! Always ground generator

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

! If unit does not have GFCI re-

ceptacles, use GFCI-protected
extension cord.

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

Mounting:

1 Cross-Supports
Mount unit on flat surface or use

cross-supports to support base.

Grounding:

2 Equipment Grounding Terminal

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

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

Inadequate support.

Grounding

GND/PE

OM-492 Page 16

! Do not use flexible mounts.

2

3

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

4

OR

1

! 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.

install2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712

5-2. Engine Prestart Checks

Full

1/2 in

(13 mm)

Full

Diesel

Check radiator coolant

level when fluid is low

in recovery tank.

Full

Capacity

w/Overflow Tank

6.4 qt (6 L)

Check all fluids daily. Engine must be cold
and on a level surface. Unit is shipped with
10W30 engine oil.

Engine stops if oil pressure is too low or en­gine temperature is too high.

 This unit has a low oil pressure shut-

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

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

Fuel

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

Add fresh 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.

Do not run out of fuel or air enters fuel sys­tem and causes starting problems. See en­gine manual to bleed air from fuel system.

Oil

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

NOTICE − Engine may use oil and wets-
tacking may occur during run-in period.
Check oil several times daily during run-in.

Coolant

Check coolant level in recovery tank before
starting unit the first time. Add coolant if
coolant is below bottom of radiator filler neck
(see Section 5-3 for radiator filling instruc­tions.

Check coolant in recovery tank daily. If cool­ant is below Full level, add coolant until cool­ant level in tank is between Full and Low lev­els. If recovery tank coolant level was low,
also check coolant level in radiator (see
Section 5-3).

Engine coolant is a mixture of water and
ethylene glycol base antifreeze. A solution
of 50% antifreeze and 50% water must be
used in this engine. Do not use 100% anti­freeze or severe damage will occur.

Full

802 330-G

Keep radiator and air intake clean and free
of dirt.

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

 To improve cold weather starting:

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

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

Use correct grade oil for cold weather
operation (see Section 6-6).

OM-492 Page 17

5-3. Adding Coolant To Radiator

1

Capacity

w/Overflow Tank

6.4 qt (6 L)

Full

! Stop engine and let cool.

 Check coolant level according

to Section 5-2 before starting
this procedure.

If coolant level is below bottom of
radiator filler neck, add coolant as
follows:

1 Radiator Air Bleed Screw
Remove radiator air bleed screw.

Add coolant to radiator until coolant
is at bottom of filler neck. This en­sures all air is purged from the sys­tem.

Reinstall screw and radiator cap.
Check coolant level in recovery
tank (see Section 5-2).

Engine coolant is a mixture of water
and ethylene glycol base anti­freeze. A solution of 50% antifreeze
and 50% water must be used in this
engine. Do not use 100% antifreeze
or severe damage will occur.

Tools Needed:

5-4. Connecting The Battery

! Connect

negative (−)
cable last.

−

Ref. 802 330-G

+

OM-492 Page 18

Tools Needed:

3/8, 1/2 in

Ref. 213 263-B / 802 330-G / Ref. S-0756-D

5-5. Installing Exhaust Pipe

 Point exhaust pipe in desired

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

Notes

Tools Needed:

1/2 in

802 173-B / Ref. 213 263-B

OM-492 Page 19

5-6. Connecting To Weld Output Terminals

! Stop engine.

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

! Failure to properly connect weld

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

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

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

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

Stick And TIG Welding

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

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

MIG And FCAW Welding

For MIG welding Direct Current Electrode
Positive (DCEP), connect wire feeder
cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on
right.

For MIG and FCAW Direct Current Elec­trode Negative (DCEN), connect wire
feeder cable to Negative (−) terminal on
right and work cable to Positive (+) termi­nal on left.

Tools Needed:

6

3

4

5

Correct Installation

3/4 in

Do not place

anything between

weld cable terminal

and copper bar.

21

Incorrect Installation

OM-492 Page 20

80801 941 / Ref. 213 263-B / 802 174-E / 803 778-A

5-7. Selecting Weld Cable Sizes*

Weld Output

ld

y

sized, or poorly

E

F

A/V

100 ft (30 m) or Less

10 − 60%

Duty

Cycle

Terminals

! Turn off power before

connecting to we
output terminals.

! Do not use worn,

damaged, under­sized, or poorl
spliced cables.

Welding

Amperes

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

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

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

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

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

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

Not Exceeding***

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

60 − 100%

Duty

10 − 100% Duty Cycle

Cycle

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

400 ft

(120 m)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

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

* This chart is a general guideline and may not suit all applications. If cable(s) 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. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

5-8. Remote 14 Receptacle RC14 Information

 Engine runs at weld/power speed whenever a device connected to the remote 14 receptacle is running.

Socket* Socket Information

A 24 volts ac. Protected by supplementary protector

CB6.

B Contact closure to A completes 24 volts ac

contactor control circuit.

I 115 volts ac. Protected by supplementary protec-

tor CB5.

J Contact closure to I completes 115 volts ac

contactor control circuit.

C Output to remote control; 0 to +10 volts dc, +10

volts dc in MIG mode.

D Remote control circuit common.

E 0 to +10 volts dc input command signal from

remote control.

AJ

K

B

L

NH

C

M

D

F

24 VOLTS AC

I

G

115 VOLTS AC

REMOTE

OUTPUT

CONTROL

*The remaining sockets are not used.

M CC/CV select.

A/V

AMPERAGE

VOLTAGE

802 174-G

GND

F Current feedback; +1 volt dc per 100 amperes.

H Voltage feedback; +1 volt dc per 10 output recep-

tacle volts.

G Circuit common for 24 and 115 volts ac circuits.

K Chassis common.

OM-492 Page 21

5-9. Guidelines For Installing Customer-Supplied Emergency Air Shutdown Valve

A customer-supplied emergency air shutdown
valve can be installed to stop the engine imme­diately in emergency situations.

These guidelines show the typical installation of
a Gator ESD 175-275-L3 air shutdown valve.
Installation of other air shutdown valves may
differ from that shown. Contact the air shut­down valve manufacturer or a Factory Autho­rized Service Agent for additional installation
and operation information.

! Stop engine, and let cool.
! Disconnect battery negative (−) cable.

Open doors and remove side panels.
1 Air Cleaner
2 2 in (51 mm) Hose Clamp
3 1-3/4 x 2 in (44 x 51 mm) Rubber Hose
4 Air Shutdown Valve

(Gator ESD 175-275-L3)

5 1-3/4 x 16-1/2 in (44 x 419 mm) Flexible

Radiator Hose (NAPA Part No. FM68)

 Use thick-walled rubber hose. Do not use

heater hose. (Heater hose could let dirt into
engine.)

6 Engine Air Inlet

7

7 Shutdown Control
8 42 in (1067 mm) Shutdown Control Cable

(Supplied By Gator)
9 Shutdown Valve Reset Lever
Install components as shown.
Be sure air shutdown valve is installed with air

flow arrow pointing toward air inlet. Use cable
ties to keep air shutdown system components
away from hot or moving parts.

Verify the emergency air shutdown system op­erates correctly. After testing, use reset lever to
reset air shutdown valve.

Reinstall side panels and close doors.
Reconnect battery negative (−) cable.

Mount on lower

front panel

OM-492 Page 22

1

2

8

3

4

9

5

7

6

803 390

5-10.Operating Engine Block Heater

1

! Do not touch hot engine

block. Engine block gets hot
near heater.

NOTICE − Do not run engine while
coolant heater is on.

2

1 Coolant Heater
2 Heater Plug
Use heater to maintain a constant

engine coolant temperature. See
table for heater specifications.

To turn on heater, connect heater
plug to a 120 volt ac grounded re­ceptacle.

To turn off heater, disconnect plug.

Coolant Heater Specifications

Watts Volts ±10% Amps

400 120 3.3

Notes

Ref. 802 330 / 803 393

Start Your Professional

Welding Career Now!

400 Trade Square East, Troy, Ohio 45373

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

Over 80,000 trained

since 1930!

OM-492 Page 23

SECTION 6 − OPERATING WELDING GENERATOR

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

13

12

45 78

6911423

10

11

OM-492 Page 24

Ref. 213 263-B / 802 330-G

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

 The fan motor is thermostatically

controlled and only runs when cooling is
needed.

Engine Lights

1 Engine Temperature Light
Light goes on and engine stops if engine tem-

perature is too high.

NOTICE − Stop engine and fix trouble if En-
gine Temperature light goes on.

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

is too low. Light goes on momentarily during
start-up but goes out when engine reaches
normal oil pressure.

NOTICE − Stop engine and fix trouble if En-
gine Oil Pressure light stays on after start-up.

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

ing battery. Engine continues to run.

NOTICE − Stop engine and fix trouble if Bat-
tery Charging light goes on.

Engine Gauges

4 Engine Hour Meter
Use hour meter to help schedule routine main-

tenance.
5 Fuel Gauge

Weld Controls

6 Dig/Inductance Control
Control adjusts Dig when Stick mode is se-

lected on mode switch. When control is set to­ward minimum, short-circuit amperage at low
arc voltage is the same as normal welding
amperage.

When set toward maximum, short-circuit am­perage is increased at low arc voltage to as­sist with arc starts and help prevent the elec­trode from sticking while welding (see volt-am­pere curves in Section 4-4).

Select setting best suited for application.
Control adjusts inductance when MIG or

V-Sense Feeder position is selected on the

mode switch. Inductance determines the
“wetness” of the weld puddle. When set to­ward maximum, “wetness” (puddle fluidity) in­creases.

Control is not functional when Pulsed MIG or
one of the TIG modes is selected.

7 Voltmeter
Meter displays weld voltage and help mes-

sages (see Sections 6-3 and 8-10).
8 Ammeter
Meter displays weld amperage and help mes-

sages (see Sections 6-3 and 8-10).
9 V/A (Voltage/Amperage) Adjustment

Control
10 Mode Switch
The Mode switch setting determines both the

process and output On/Off control (see Sec­tion 6-4). Source of control (panel or remote)
for the amount of output is selected by the V/A
Control switch.

For Air Carbon Arc (CAC-A) cutting and goug­ing, place switch in Stick position. For best re­sults, place Dig/Inductance control in the max­imum position.

11 V/A (Voltage/Amperage) Control Switch

And Remote 14 Receptacle
For front panel control, place switch in Panel

position and use the V/A Adjustment control.
For remote control, make connections to Re-

mote 14 receptacle (see Section 5-8), and
place switch in Remote position. In most
modes, remote control is a percent of V/A Ad­justment control setting (value selected on
V/A Adjustment control is maximum available
on remote). In the MIG mode, remote control
provides full range of unit output regardless of
V/A Adjust control setting.

Engine Starting Controls

12 Glow Plug Switch
Use switch to energize glow plugs for cold

weather starting. Glow plugs warm in about
six seconds and engine can be started (see
starting instructions following).

NOTICE − Do not use glow plug longer than
20 seconds.

13 Engine Control Switch
Use switch to start engine, select speed, and

stop engine. In Run/Idle position, engine runs
at idle speed at no load, and weld/power
speed under load. In Run position, engine
runs at weld/power speed.

To Start:

NOTICE − Do not use ether as a starting aid.
Using ether voids warranty.

Above 325 F: turn Engine Control switch to
Start. Release switch when engine starts and
Engine Oil Pressure light goes out.

 If engine does not start, let engine come

to a complete stop before attempting re­start.

Below 325 F: turn engine control switch to
Run/Idle position. Push Glow Plug switch up
and hold about six seconds. Turn Engine Con­trol switch to Start. Release switch when en­gine starts and Engine Oil Pressure light goes
out.

See Section 6-6 for additional information on
cold weather operation.

 If engine does not start, let engine come

to a complete stop before attempting re­start.

To Stop: turn Engine Control switch to Off
position.

 Push engine stop lever to stop engine if

Engine Control switch does not work (see
item 14).

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

switch does not work.

OM-492 Page 25

6-3. Meter Functions

Mode Switch S

P

O

/Off C

l

 The meters display the actual weld output values for approximately three seconds after the arc is broken.

Mode Meter Reading At Idle Meter Reading While Welding

VA

10.3 85

Actual Volts Actual Amps

VA

10.3 85

Actual Volts Actual Amps

VA

10.3 85

Actual Volts Actual Amps

VA

24.5 250

Actual Volts Actual Amps

VA

24.5 250

Actual Volts Actual Amps

VA

24.5 85

Actual Volts Actual Amps

VA

24.5 85

Actual Volts Actual Amps

VA

24.5 250

Actual Volts Actual Amps

Scratch

Start TIG

Lift-Arc TIG

TIG

MIG

Pulsed

MIG

CC

Stick

V-Sense

Feeder

VA

80.0 85

Actual Volts (OCV) Preset Amps

VA

7.0 85

Actual Volts Preset Amps

VA

85

Blank Preset Amps

VA

24.5

Preset Volts Blank

VA

PPP PPP

Pulse Display Pulse Display

VA

85

Blank Preset Amps

VA

80.0 85

Actual Volts (OCV) Preset Amps

VA

80.0

Flashes OCV And Preset Blank

6-4. Mode Switch Settings

 The Stick and CC modes provide the Adaptive Hot Start™ feature, which automatically increases the output amperage at the start of a weld should

the start require it. This eliminates electrode sticking at arc start.

etting

Scratch Start TIG GTAW Electrode Hot

Lift-Arc TIG GTAW − See Section 6-5 Electrode Hot

TIG GTAW With HF Unit, Pulsing Device, Or Remote Control At Remote 14

MIG GMAW At Remote 14

Pulsed MIG GMAW-P (Requires an external pulsing device.) At Remote 14

CC Stick (SMAW) With Remote On/Off At Remote 14

Stick SMAW Electrode Hot

V-Sense Feeder MIG (GMAW) With Voltage Sensing Wire Feeder Electrode Hot

rocess

utput On

ontro

OM-492 Page 26

6-5. Lift-Arc TIG Procedure

“Touch”

1

1 − 2

Seconds

With Mode Switch in the Lift-Arc
TIG position, start an arc as follows:

2

1 TIG Electrode
2 Workpiece
Touch tungsten electrode to work-

piece at weld start point, hold

electrode to workpiece for 1-2
seconds, and slowly lift electrode.

An arc will form when electrode is
lifted.

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

Do NOT Strike Like A Match!

6-6. Recommendations For Extreme Cold Weather Operation

 For more information on operating in cold

weather, contact the nearest Factory Au­thorized Service Agent or Kubota Service
Center.

Fuel

 Use an arctic-grade diesel fuel and keep

fuel tank at least half full to prevent fuel
lines from draining back into tank.

 Do not use gasoline or kerosene.

 Do not use fuel additives.

Oil

 Use 10W30 oil when operating at ambient

temperatures above -4° F (−20° C).

 Use 5W30 oil when operating at ambient

temperatures above -13° F (−25° C).

 Operating at extremely low temperatures

thickens engine oil and reduces cranking
speed. Contact a Factory Authorized Ser­vice Agent or Kubota Service Center for
information on using 0W20 oil in these
conditions. Low temperature oil must be
replaced as ambient operating tempera­tures increase.

Coolant

 Be sure the cooling system is completely

filled with a 50/50 antifreeze/water mix
(open the radiator vent when filling). Do
not mix antifreeze and water solution in
the overflow tank. Use a premixed 50/50
antifreeze/water solution to “top off” over­flow tank. Use caution if rerouting cooling
lines. Engine damage due to lack of

coolant or incorrect coolant mix is not
covered by the warranty.

 A 50/50 antifreeze/water mix protects en-

gine to -34°F (−37°C). If operating at even
lower temperatures, contact a Factory
Authorized Service Agent or Kubota Ser­vice Center for coolant information.

Battery

 Replacement Battery Rating: 12 Volt, 535

CCA (minimum) 90 RSV Group 55.

 Check connections at battery, starter, and

engine block. Inspect battery cables for
abrasion and wear, and verify the battery
is secured.

 Consider installing easily-accessible bat-

tery booster leads (0 or 00 AWG) to pro­vide easy connection to a service truck’s
battery.

 Boost the starting capability of the battery

by using a battery heater.

Starting

 Do not use ether.

 Use the engine block heater to maintain

engine temperature above ambient tem­perature.

 Use the glow plugs for 20−30 seconds be-

fore starting. As a preseason check,
make sure the glow plugs are working
properly.

 Disconnect all unnecessary loads from

generator ac receptacles when starting.

Ref. S-156 279

Operating

 To reduce crankcase condensation and

breather tube freezing problems, allow
engine to reach normal operating temper­ature as quickly as possible.

 Crankcase breather tubes will collect

condensation and freeze if the hose is im­properly routed. The breather tube should
be free of sharp bends and kinks. A
blocked breather tube will cause exces­sive crankcase pressure that will blow out
the safety plug, oil seals, or dipstick. Con­tact a Factory Authorized Service Agent
to obtain a shorter breather hose that is
less likely to kink.

 Inspect the routing and condition of the

breather tube frequently. Reroute or re­place the hose if necessary.

 For continuous use in extreme cold, block

the cooling holes in the base to reduce air
flow through the radiator and achieve
higher engine temperature. Close off the
base inlet vents only if the engine coolant
or oil temperatures can be monitored to
ensure they remain within the specified
limits.

 To obtain warmer air for combustion, turn

the air cleaner inlet away from the inlet
vents, and seal the inlet vents.

 If operating in cold weather all the time,

consider replacing the existing radiator
cooling fan with a smaller fan that draws
less air through the radiator. Operation in
warmer temperatures would require an
additional “booster” electric fan to ade­quately cool the engine.

OM-492 Page 27

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Receptacles And Circuit Breakers

1236 45

SIMULTANEOUS WELDING AND AUXILIARY POWER

Weld

Current

In Amperes

350
300
250
200
150
100

50

0

Total

Power

In Watts

11900

9600
7500
5600
3900
2400

1100

0

120 V

Receptacle

Amperes

16
38
40
40
40
40
40

Single-Phase

Receptacle

−

240 V

Amperes

−

5
15
30
35
40
45
50

7

8

Three-Phase

240 V

Receptacle

Amperes

−

4
10
13
19
23
26
30

! If unit does not have GFCI recep-

tacles, use GFCI-protected exten­sion cord.

 Generator power decreases as weld

current increases.

1 240 V 50 A AC Receptacle RC1
RC1 supplies 60 Hz single-phase power at

weld/power speed. Maximum output is 12
kVA/kW.

2 120 V 20 A AC Duplex Receptacle

RC2

3 120 V 20 A AC Duplex Receptacle

RC3

RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum out-

OM-492 Page 28

put from RC2 or RC3 is 2.4 kVA/kW.
4 240 V 30 A, AC Twistlock Receptacle

RC4

RC4 supplies 60 Hz three-phase power at
weld/power speed. Maximum output is 12
kVA/kW.

5 Supplementary Protector CB1
CB1 protects RC1, RC2, and RC3 from

overload. If CB1 opens, RC1, RC2, and
RC3 do not work. Place switch in On posi­tion to reset.

6 Supplementary Protectors CB2 And

CB3

CB2 protects RC2 and CB3 protects RC3
from from overload. If CB2 or CB3 opens,
the receptacle does not work. Press button
to reset.

213 263-B

7 Supplementary Protector CB4
CB4 protects RC4 from overload. If CB4

opens, the receptacle does not work. Place
switch in On position to reset.

 If a supplementary protector continues

to open, contact Factory Authorized
Service Agent.

Combined output of all receptacles limited
to 12 kVA/kW rating of the generator.

EXAMPLE: If 13 A is drawn from RC2 and
RC3, only 37 A is available at RC1:

2 x (120 V x 13 A) + (240 V x 28 A) = 12
kVA/kW

8 Generator Power While Welding

Table

7-2. Optional GFCI Receptacles And Circuit Breakers

12

! If unit does not have GFCI

receptacles, use GFCI-pro­tected extension cord.

 Generator power decreases as

weld current increases.

1 120 V 20 A AC GFCI Duplex

Receptacle GFCI-2

2 120 V 20 A AC GFCI Duplex

Receptacle GFCI-3

GFCI-2 and GFCI-3 supply 60 Hz
single-phase power at weld/power
speed. Maximum output from
GFCI-2 or GFCI-3 is 2.4 kVA/kW.
Circuit protection is the same as
standard receptacles.

If a ground fault is detected, the GFCI
Reset button pops out and the circuit
opens to disconnect the faulty equip­ment. 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 en-

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

Ref. ST-207 554-A

7-3. Wiring Instructions For Optional 240 Volt, 3-Phase Twistlock Plug (NEMA L15-30P)

1 240 V AC Three-Phase, 30 A,

1

5

4

240V

6

240V

240V

3

3P4W Twistlock Plug
2 Load 1 (Brass) Terminal (X)
3 Load 2 (Brass)Terminal (Y)
4 Load 3 (Brass) Terminal (Z)
5 Ground (Green) Terminal (G)
6 Cord Grip
Strip cord jacket back enough to sep-

arate conductors.
Strip conductors enough to make

2

good contact with plug terminals.
Make plug connections and reinstall
cord grip.

Tighten cord grip assembly screws.
Do not overtighten.

Tools Needed:

Plug2 7/99 − 802 437

OM-492 Page 29

7-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)

The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.

1 Plug Wired for 120/240 V,

3-Wire Load

When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.

2 Plug Wired for 240 V, 2-Wire

Load
3 Neutral (Silver) Terminal
4 Load 1 (Brass)Terminal
5 Load 2 (Brass) Terminal
6 Ground (Green) Terminal
7 Amperes Available using

120/240 V Plug

5

Tools Needed:

Current Available in Amperes

240 V

Receptacle*

0

5
10
15
20
25
30
35
40

Each 120 V Duplex

Receptacle

20
20
20
20
20
15
10

5
0

V x A = Watts

*One 240 V load or two 120 V loads.

7

3

4

120V

120V

240V

4

1

6

2

3

240V

240 V AC

120 V AC 120 V AC

56

OM-492 Page 30

plug1 11/03 − 120 813-D

SECTION 8 − MAINTENANCE AND TROUBLESHOOTING

8-1. Maintenance Label

OM-492 Page 31

8-2. Routine Maintenance

Recycle engine

fluids.

! Stop engine before maintaining.

 See Engine Manual and Maintenance Label

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

Every

8

Hours

Every

50

Hours

Every

100

Hours

Every

200

Hours

 = Check  = Change  = Clean  = Replace

 Coolant Level  Fuel Level  Oil Level  Oil, Fuel Spills

 Fuel Connections  Weld Terminals  Spark Arrestor Screen

 Air Cleaner Element  Air Cleaner Hoses  Belt Tension  Battery Terminals

 Oil  Oil Filter  Radiator Hoses  Unreadable Labels

* To be done by Factory Authorized Service Agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5/16 in.
(8 mm)

Reference

Section 5-6

Section 8-3

Section 8-4,
Engine
Manual

Section 8-5,
8-6

Every

400

Hours

Every

500

Hours

Every

800

Hours

Every

1000

Hours

Every

2000

Hours

 Primary Fuel Filter

 Secondary Fuel Filter

LUDGE

 Fan Belt  Flush Radiator  Weld Cables  Drain Sludge

 Valve Clearance*

OR

 Inside Unit  Slip Rings*

 Brushes*

FUEL

Section 8-5

Engine
Manual,
Section 8-5,
8-6

Engine
Manual

Section 8-6,
Engine
Manual

 Coolant And Hoses  Fuel Lines And Clamps

OM-492 Page 32

8-3. Servicing Spark Arrestor

1

Tools Needed:

! Stop engine and let cool.

1 Cleanout Plug
Remove plug and remove any dirt

covering cleanout hole.
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.

1/4 in

Ref. 213 263-B-B / 802 743 / Ref. 802 656

OM-492 Page 33

8-4. Servicing Air Cleaner

Keep nozzle

2 in (51 mm)

from element.

Blow Inspect

! 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).

OM-492 Page 34

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

8-5. Servicing Engine Lubrication And Fuel Systems

4

FLOW

1

3

6

7

5

4

8

! Stop engine and let cool.

1 Oil Filter
2 Oil Drain Valve
3 1/2 ID x 12 in Hose
4 Fuel Line
5 Primary Fuel Filter
6 Secondary Fuel Filter
7 Petcock
8 Fuel Tank Sludge Drain

To change oil and filter:

Pull oil drain hose through access hole in
base. Change engine oil and filter according
to instructions in engine manual.

NOTICE − Close valve and valve cap be-
fore adding oil and running engine.

Fill crankcase with new oil to full mark on
dipstick (see Section 5-2).

2

To drain water from fuel system:

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

To change fuel filters:

Install new primary fuel filter as shown.

Replace secondary fuel filter according to
engine manual.

Replace fuel lines if cracked or worn.

Wipe up any spilled fuel.

! After servicing, start engine and

check for fuel leaks.

Stop engine, tighten connections as
necessary, and wipe up fuel.

Tools Needed:

9/16 in

Ref. 213 263-B / 802 330-G / S-0842

To change coolant:

Change coolant according to engine
manual.

Run engine until engine reaches normal op­erating temperature. Loosen air bleed
screw to remove air from cooling system.
Tighten screw.

Check coolant level in recovery tank. Add
coolant if necessary.

To drain sludge from fuel tank:

Put metal container under drain, and re­move sludge drain plug. Reinstall plug
when done.

OM-492 Page 35

8-6. Servicing Engine Cooling System

! Stop engine and let cool.

1 Radiator Draincock
2 Radiator Cap
3 Radiator Air Bleed Screw
Change coolant according to engine

manual. Add coolant according to Sec­tion 5-3).

Run engine until engine reaches normal
operating temperature. Loosen air bleed
screw to remove air from cooling system.
Tighten screw.

Check coolant level in recovery tank. Add
coolant if necessary

1

3

2

OM-492 Page 36

802 330-G / 802 581

8-7. Replacing Throttle Solenoid TS1

1

8

2

6 345

! Stop engine, and let cool.
! Disconnect battery, negative

(−) cable first.

Remove right side engine panel.
1 Plug PLG39/Receptacle RC39
2 Throttle Solenoid TS1
3 Shoulder Bolt And Nut
4 Throttle Link
5 Throttle Solenoid Plunger Rod
6 Jam Nut
7 Throttle Arm
8 Throttle Arm Stop Screw
Disconnect solenoid plug PLG39

from wiring harness receptacle
RC39.

Remove shoulder bolt and nut from
throttle link.

Remove solenoid from mounting
bracket.

Note how much thread is visible on
solenoid plunger rod. Loosen jam nut
just enough so throttle link can be re­moved from solenoid rod.

Install throttle link on new solenoid
plunger rod. Turn link until the same
amount of thread will be visible on
plunger rod when the jam nut is tight­ened. (Do not tighten jam nut yet.)

Mount solenoid on bracket. Move so­lenoid plunger manually to align slot
in throttle link with hole in throttle arm.
Insert shoulder bolt through slot/hole
and secure with nut.

 Be sure solenoid plunger rod

pulls all the way in “bottoms”
when energized. If plunger rod
does not pull all the way in, re­adjust throttle link.

 Throttle arm should not contact

7

stop screw when solenoid is en­ergized. If necessary, adjust
stop screw to create gap be­tween throttle arm and stop
screw.

Tighten jam nut on solenoid plunger
rod. Verify all other hardware is tight.

Connect solenoid plug PLG39 to wir­ing harness receptacle RC39.

Reconnect battery, negative (−) lead
last.

Check engine speeds and adjust if
necessary according to Section 8-8.

Reinstall side panel.

Tools Needed:

7/16, 3/8, 1/2 in
10 mm

3/16 in

OM-492 Page 37

802 330-B

8-8. Adjusting Engine Speed

After tuning engine, check engine
speeds with a tachometer (see table).
If necessary, adjust speeds as follows:

2500 rpm (41.6 Hz)

3750 Max (62.5 Hz)

Start engine and run until warm. Turn
V/A control to max.

Adjusting Idle Speed

Idle speed is factory set and normally
does not not require adjustment unless
the governor/injector pump or throttle
solenoid is replaced.

1 Throttle Link
2 Throttle Solenoid Plunger Rod
3 Jam Nut
4 Throttle Arm Stop Screw
Turn Engine Control switch to Run/Idle

position. Loosen jam nut and turn sole­noid rod clockwise (into throttle link) to
decrease idle speed. Turn rod counter­clockwise to increase idle speed.
Tighten nut.

 Be sure solenoid plunger rod pulls

all the way in “bottoms” when en­ergized. If plunger rod does not
pull all the way in, readjust rod and
throttle link.

 Throttle arm should not contact

stop screw when solenoid is ener­gized. If necessary, adjust stop
screw to create gap between
throttle arm and stop screw.

Adjusting Weld/Power Speed

5 Throttle Solenoid
6 Weld Speed Jam Nut
7 Adjustment Screw
Turn Engine Control switch to Run

position. Loosen nut and turn screw
counterclockwise to increase speed.
Turn screw clockwise to decrease

6

7

4

speed. Tighten nut.

Using Engine Stop Lever

8 Engine Stop Lever
Use lever to stop engine if Engine Con-

trol switch does not work.

OM-492 Page 38

5

8

312

Tools Needed:

10 mm

802 330-B

8-9. Overload Protection

Tools Needed:

3/8 in

1

! Stop engine.

 When a supplementary protec-

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

1 Supplementary Protector CB5
CB5 protects the 115 volt ac output

to Remote 14 receptacle RC14. If
CB5 opens, 115 volt ac output to
RC14 stops.

2 Supplementary Protector CB6
CB6 protects the 24 volt ac output

to Remote 14 receptacle RC14. If
CB6 opens, 24 volt ac output to
RC14 stops.

Press button to reset.

2

3 Circuit Breaker CB7
4 Circuit Breaker CB8
5 Supplementary Protector

CB10

CB7 protects the engine glow plug
from overload. If CB7 opens, the
glow plug does not work and engine
may not start in cold weather.
Check continuity and connections
of engine glow plug.

CB8 protects the engine wiring sys­tem from overload. If CB8 opens,
the engine will not crank. Check
battery, starter, and engine control
switch.

CB10 protects the engine fuel sole­noid from overload. If CB10 opens,
the engine cranks but does not
start. Check fuel solenoid FS1 for
obstructions.

5 4

3

Ref. 213 263-B-B / 802 174-E / 802 175-D

OM-492 Page 39

8-10.Voltmeter/Ammeter Help Displays

1

HE.L P−0

2

HE.L P−1

3

HE.L P−2

4

HE.L P−3

AV

6

AV

HE.L P−5

AV

7

AV

HE.L P−6

AV

8

AV

HE.L P−7

AV

9

AV

HE.L P−8

Use the voltmeter/ammeter help displays to
help determine the cause of no weld output.
When a help display is shown, the inverter
module weld output has stopped but the en­gine continues to run. Correct the problem
before resuming operation.

The display screen resets when the fault is
corrected.

 All directions are in reference to the front

of the unit. All circuitry referred to is lo­cated inside the inverter module.

1 Help 0 Display

Indicates a shorted thermistor RT2 on the left
side of the unit. If this display is shown, con­tact a Factory Authorized Service Agent.

2 Help 1 Display

Indicates a malfunction in the primary power
circuit possibly caused by applying a high
weld load at idle speed. Turn Engine Control
switch to Run position. If problem continues,
contact a Factory Authorized Service Agent.

AV

5

HE.L P−4

3 Help 2 Display

Indicates a malfunction in the thermal protec­tion circuitry located on the left side of the unit.
If this display is shown, contact a Factory Au­thorized Service Agent.

4 Help 3 Display

Indicates the left side of the unit has over­heated. The unit has shut down to allow the
fan to cool it (see Section 4-3). Operation will
continue when the unit has cooled.

5 Help 4 Display

Indicates a malfunction in the thermal protec­tion circuitry located on the right side of the
unit. If this display is shown, contact a Factory
Authorized Service Agent.

6 Help 5 Display

Indicates the right side of the unit has over­heated. The unit has shut down to allow the
fan to cool it (see Section 4-3). Operation will
continue when the unit has cooled.

AV

10

HE.L P−9

802 174-G

7 Help 6 Display
Indicates that the input voltage is too low and

the unit has automatically shut down. Opera­tion will continue when the voltage is within the
acceptable lower range limit (15% below the
applicable input voltage). If this display is
shown, have a Factory Authorized Service
Agent check the power generator output volt­age.

8 Help 7 Display
Indicates that the input voltage is too high and

the unit has automatically shut down. Opera­tion will continue when the voltage is within the
acceptable upper range limit (15% above the
applicable input voltage). If this display is
shown, have a Factory Authorized Service
Agent check the power generator output volt­age.

9 Help 8 Display
Indicates a malfunction in the secondary pow-

er circuit of the unit. If this display is shown,
contact a Factory Authorized Service Agent.

10 Help 9 Display
Indicates a shorted thermistor RT1 on the

right side of the unit. If this display is shown,
contact a Factory Authorized Service Agent.

OM-492 Page 40

8-11.Troubleshooting

A. Welding

Trouble Remedy

No weld output. Check control settings.

Check weld connections.

Disconnect equipment from generator power receptacles during start-up.

If using remote control, be sure mode switch is in a position that provides output control at Remote 14
receptacle (see Sections 5-8 and 6-1).

Check, repair, or replace remote control.

Unit overheated. Allow unit to run so fan cools unit (see Section 4-3).

Have Factory Authorized Service Agent check brushes, slip rings, power board PC7, voltage regulator
board PC8, interconnecting board PC2, and control board PC1.

Ammeter and voltmeter do not work
after unit has run out of fuel.

Low weld output. Check control settings.

High weld output. Check control settings.

Weld output cannot be adjusted. Check position of V/A Control switch (see Section 6-1).

Erratic weld output. Check control settings.

Restart the engine.

Place V/A Control switch in Panel position, or move switch to Remote position and connect remote
amperage/voltage control to Remote 14 receptacle RC14 (see Section 5-8).

Check and clean air cleaner as necessary (see Section 8-4).

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

If using remote control, be sure mode switch is in a position that provides output control at Remote 14
receptacle RC14 (see Sections 5-8 and 6-1).

Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, intercon­necting board PC2, and control board PC1.

See engine manual.

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

Check for obstructed movement of throttle solenoid linkage.

Have Factory Authorized Service Agent check voltage regulator board PC8 and control board PC1.

Have Factory Authorized Service Agent check voltage regulator board PC8 and control board PC1.

Clean and tighten connections both inside and outside unit.

Check and secure lead connections to A/V control.

Be sure connection to work piece is clean and tight.

Remove excessive coils from weld cables.

Use dry, properly stored electrodes.

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

Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, intercon­necting board PC2, and control board PC1.

OM-492 Page 41

Trouble Remedy

Remote contactor control does not
activate contactor.

Check and tighten connections to Remote 14 receptacle RC14 (see Section 5-8).

Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Weld­ing arc.

Wandering arc − poor control of arc
direction.

Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.

No 115 volt ac output at Remote 14 re­ceptacle RC14.

No 24 volt ac output at Remote 14 re­ceptacle RC14.

Use proper size tungsten for welding amperage.

Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).

Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.

Reduce gas flow rate.

Select proper size tungsten. Properly prepare tungsten.

Shield weld zone from drafts.

Increase postflow time.

Check and tighten all gas fittings.

Properly prepare tungsten.

Reset supplementary protector CB5 (see Section 8-9).

Reset supplementary protector CB6 (see Section 8-9).

B. Generator Power

Trouble Remedy

No power output. Reset supplementary protectors (see Section 7-1).

Have Factory Authorized Service Agent check brushes, slip rings, power board PC7, voltage regulator
board PC8, interconnecting board PC2, and control board PC1.

Low power output. Check air cleaner, and clean or replace element if necessary.

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

See engine manual.

High power output. Check engine speed, and adjust if necessary (see Section 8-8).

Erratic power output. Check receptacle wiring and connections.

Check governor according to engine manual.

Have Factory Authorized Service Agent check brushes, slip rings, power board PC7, voltage regulator
board PC8, interconnecting board PC2, and control board PC1.

OM-492 Page 42

C. Engine

Trouble Remedy

Engine will not crank. Reset circuit breaker CB8 (see Section 8-9).

Check battery voltage.

Check battery connections and tighten if necessary.

Have Factory Authorized Service Agent check Engine Control switch S2.

Engine cranks, but does not start. Check fuel level (see Section 5-2).

Open fuel valve (see Section 5-2).

Check oil level (see Section 5-2). Engine will not start if oil pressure is low.

Reset supplementary protector CB10 (see Section 8-9).

Check coolant level and fan belt (see Section 5-2 and engine manual). Engine will not start if coolant
temperature is high.

Use Glow Plug switch if unit does not start in cold weather. If unit still does not start, reset circuit
breaker CB7 (see Section 8-9).

Service primary and secondary fuel filters (see Section 8-5).

Check battery and replace if necessary.

Check engine charging system according to engine manual.

Bleed air from fuel system according to engine manual.

Reset customer-supplied emergency air shutdown valve (if equipped) (see Section 5-9).

Have Factory Authorized Service Agent check low oil pressure switch S5, engine coolant tempera­ture switch S4, and control relay CR1.

See engine manual.

Engine starts, but stops when Engine
Control switch returns to Run position.

Engine does not stop. Stop engine by pushing down engine stop lever (see Section 5-2) or closing fuel valve (see Section

Engine stopped during normal
operation.

Battery discharges between uses. Clean top of battery with baking soda and water solution; rinse with clear water.

Check oil level (see Section 5-2). Engine will not start if oil pressure is too low.

Check coolant level and fan belt (see Section 5-2 and engine manual). Engine will not start if engine
temperature is too high.

Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see en­gine manual).

Have Factory Authorized Service Agent check low oil pressure switch S5, engine coolant tempera­ture switch S4, Engine Control switch S2, control relay CR1, and voltage regulator board PC8.

5-2). After stopping engine, adjust fuel solenoid linkage (see engine manual).

Check fuel level (see Section 5-2).

Open fuel valve (see Section 5-2).

Check oil level (see Section 5-2). Engine stops if oil pressure is too low.

Check coolant level and fan belt (see Section 5-2 and engine manual). Engine stops if engine temper­ature is too high.

Bleed air from fuel system according to engine manual.

Have Factory Authorized Service Agent check low oil pressure switch S5 and engine coolant temper­ature switch S4.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator according to engine manual.

OM-492 Page 43

Trouble Remedy

Engine does not go to low (idle) speed
with Engine Control switch in Run/Idle
position.

Be sure Engine Control switch S2 is in Run/Idle position.

Remove all weld and generator power loads.

Turn off remote device connected to Remote 14 receptacle RC14 (see Section 5-8).

Check for obstructed movement of throttle solenoid linkage.

Have Factory Authorized Service Agent check voltage regulator board PC8 and current transformer
CT1.

Engine does not go to high (run) speed
when generator power or large weld
load is applied with Engine Control
switch in Run/Idle position.

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

Coolant recovery tank continuously
overflows.

Notes

Place Engine Control switch in the Run position. Have Factory Authorized Service Agent check unit.

Dry engine (see Section 10 and engine manual).

Bleed air from radiator, and replace lost coolant (see Section 5-3).

OM-492 Page 44

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-492 Page 45

SECTION 9 − ELECTRICAL DIAGRAMS

OM-492 Page 46

Figure 9-1. Circuit Diagram For Welding Generator

OM-492 Page 47

212 633-F

10-1. Wetstacking

1

SECTION 10 − RUN-IN PROCEDURE

! Do not perform run-in

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

2

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_in4 2007−05

OM-492 Page 48

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.

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

1

occur.

1 Load Bank
Turn all load bank switches Off. If

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

2 Welding Generator
3 Weld Cables
Connect load bank to generator

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

Start engine and run for several
minutes.

Set load bank switches and then
adjust generator V/A control so load
equals 225 amps at 30 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 V/A 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-492 Page 49

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.

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

1 Resistance Grid
Use grid sized for generator rated

1

output.
Turn Off grid.
2 Welding Generator
3 Weld Cables
Connect grid to generator weld

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

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

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

minutes.
Set grid switches and then adjust

generator V/A control so load
equals 225 amps at 30 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 V/A 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-492 Page 50

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-492 Page 51

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-492 Page 52

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-492 Page 53

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-492 Page 54

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-492 Page 55

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-492 Page 56

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-492 Page 57

SECTION 12 − PARTS LIST

 Hardware is common and

not available unless listed.

3

2

105

1

16

15

14

5

6

10

9

8

7

4

21

13

11

12

18

19

20

17

93

Fig. 12-2

104

103

Fig. 12-3

95

96

97

98

94

92

22

23

99

102

101

1000

94

91

24

25

28

27

26

29

90

OM-492 Page 58

Figure 12-1. Main Assembly

30 Fig. 12-4

33

32

31

34

35

36

15

54

37

39

38

55

56

40

41

42

53

43

52

51

67

44

46

50

49

48

45

47

87

86

85

63

62

89

61

60

59

88

58

81

82

57

83

84

77

65

64

79

80

78

66

73

74

75

76

68

71

70

69

72

802 324-N

OM-492 Page 59

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-1. Main Assembly

1 +198 157 PANEL, generator left 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ♦+198 873 PANEL, generator left stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 +198 155 COVER, generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2+♦198 871 COVER, generator stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦163163 SCREW, 250−20x .50 Hex Hd−pln Stainless Pln T18−8 302−305 37. . . . . . . . . . . . . . . . . . . . . . . . . . .

♦163175 SCREW, 250−20x .75 Hex Hd−pln Stainless Pln T18−8 302−305 As Rqd.. . . . . . . . . . . . . . . . . . . . . . . .

♦163167 WASHER, Lock .254idx0.489odx.062t Stainless Split.250 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦163174 WASHER, Flat .281idx0.625odx.050t Stainless 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 233953 LABEL, warning general precautionary CSA 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 107 990 LABEL, use diesel fuel only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 198 159 TRAY, fuel spill 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 200 366 EDGE TRIM, style 70−p−11 nitrile rubber x roll 2 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 193 411 BRACE, hood access rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 198 156 DOOR, access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ♦198 872 DOOR, access stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 198 525 HINGE, door access 180deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 +198 164 HOOD, access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 +♦198 878 HOOD, access stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 194 320 LATCH, door access 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 194 295 LABEL, engine maintenance 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 198 162 PLENUM, radiator cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 ♦198 875 PLENUM, radiator cover stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 200 448 LABEL, warning steam and hot coolant 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 109 591 CLAMP, muffler 1.750dia 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 201 882 PIPE, exhaust elbow 1.654 ID stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 198 153 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 176 230 LABEL, hot exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 198 154 DOOR, access removable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 ♦198 870 DOOR, access removable stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 209 344 SEAL, lifting eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 090 281 LABEL, caution do not use ether 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 168 385 LABEL, warning battery explosion can blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 198 054 UPRIGHT, base center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 CR2 155 309 CONTACTOR, solenoid 12VDC continuous 400 A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 193 414 BRACKET, mtg gas spring front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 172 296 BALL GAS SPRING, stud .39dia 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 192 239 SPRING, pressure gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 206 795 BOOT, circuit breaker clear hex nut 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 197 265 BRACKET, mtg air cleaner and stop door access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 Figure 12-4 GENERATOR ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 193 624 ENGINE, Kubota dsl elec (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 S2 *197 145 SWITCH, oil pressure 7 psi no screw terminal (included w/engine) 1. . . . . . . . . . . . . . . . . .

114 923 BOOT, insulator term post red (for starter and alternator terminals) 2. . . . . . . . . . . . . . . . . . . . . . . . . .

33 200 653 HEATER, block engine 120v 400w kabota 905 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 S3 205 800 SWITCH, thermo temp 230deg ±5deg F NO 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 192 517 GASKET, exhaust manifold 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 192 194 PIPE, exhaust flexible inlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 191 693 GUARD, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 +202 243 SHROUD, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 191 341 HOSE, radiator outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 198 186 BRACKET, mtg radiator LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 197 822 RADIATOR, w/14# cap 3 row core 1.125 inlet/outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 194 578 BAFFLE, air foam 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 198 181 RADIATOR ARCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 191 626 BUMPER, door access 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 192 195 PIPE, exhaust outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 182 092 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 201 528 MUFFLER, exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 198 187 BRACKET, mtg radiator RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 198 185 BAFFLE, lower radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 191 342 HOSE, radiator inlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-492 Page 60

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-1. Main Assembly (Continued)

51 202 198 BASE, fuel filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 *192 744 FILTER, fuel spin-on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 187 462 BOTTLE, overflow w/cap and hose 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

208 124 CAP, w/gasket overflow bottle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 934 BRACKET, mtg coolant recovery tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 197 146 FAN, engine 330mm pusher kubota 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 *066 113 FILTER, fuel inline .250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 *196 428 FILTER, oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 192 475 SUPPORT, engine 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 192 476 MOUNT, engine vibration 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 118 829 SCREW, shld stl sch .312-18 x .500 x .375 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 194 127 LINKAGE, throttle solenoid 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 145 675 NUT, .312-18 x .50 hex .37h stl pld deformed 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 192 196 SOLENOID, 12VDC 46A push/hold (throttle) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 192 663 BRACKET, mtg solenoid 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 047 234 BOLT, banjo 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 047 235 WASHER, seal oil copper .879 ID x 1.059 OD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 203 897 HOSE, oil w/fittings 22.500 lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 165 271 VALVE, oil drain 3/8-18 NPTF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 209 329 INDICATOR, restriction air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 197 256 HOSE, elbow air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 193 026 BAND, mtg air cleaner case 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 192 188 AIR CLEANER, intake 90deg outlet 4.25 in dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*187 441 ELEMENT, air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦202 102 ELEMENT, air cleaner safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 197 227 HOSE, elbow air intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 032 453 CABLE, bat neg 24.375 No. 2 awg w/clamp and .375 rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 204 875 HOLD DOWN, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 146 237 BATTERY, stor 12V 535crk 90rsv gp 55 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 494 604 BOLT, j stl .250−20 x 8.000 pld w/nuts&washers 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 182 276 CABLE, bat pos 28.000 No. 1 awg w/clamp and .406 lug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 110 465 TUBING, corrugated plastic slit .500 dia xcoil 2.1 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

79 097829 BOLT, J Stl .250−20 X 2.750 Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 200 407 STRAP, Fuel Tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 198 168 SUPPORT, Fuel Tank/Weld Components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 198 180 TANK, Fuel 13.1 Gal (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 124 253 BUSHING, Tank Fuel 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 198 510 FTG, Stand Pipe Hose .3125 X24.570lg 90 Deg Zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 198 511 FTG, Stand Pipe Hose .1875x24.570lg 90 Deg Zinc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 190 198 CAP, Tank Screw−on 3.500 In W/Vent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 198 512 SENDER, Fuel Gauge 22.500 Deep Tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 189 908 VALVE, Drain Fuel 180 Deg Zinc Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 181 572 BUSHING, Tank Fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 197 930 LABEL, warning do not weld on base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91 197 835 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 192 477 MOUNT, engine vibration 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 Figure 12-2 FRONT PANEL ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 198 167 SUPPORT, inverter chassis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 190 861 LABEL, electric shock and moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-492 Page 61

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Figure 12-1. Main Assembly (Continued)

213 226 HARNESS, wiring ignition (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96 CR1, CR2 173 069 RELAY, encl 12VDC SPDT 30A/20A 5 pin flange mtg 2. . . . . . . . . . . . . . . . . . . . . . . .

97 197 147 BLOCK, term 5-4-3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98 D3 135 184 DIODE BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 191 735 STRIP, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG26 135 275 CONNECTOR, rect univ 084 15P/S 3 row plug (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . .

PLG5 166 680 CONNECTOR, rect univ 084 12P/S 3 row plug (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8 177 859 CONNECTOR, body 5 terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG34 153 501 CONNECTOR, rect univ 039 6P/S 3 row plug (service kit) 2. . . . . . . . . . . . . . . . . . . . . . . . . .

S6 021 467 SWITCH, tgl spst 3a 250v off−none−(on) spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 654 SEAL, wire univ 12p/s 3row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 655 SEAL, wire univ 15p/s 3row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

208 871 HARNESS, wiring engine compartment (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC5 158 466 CONNECTOR, rect univ 084 12P/S 3 row rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG38 192 170 CONNECTOR, rect 250 2skt 1 row plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 169 CONNECTOR, rect 250 1skt 1 row plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG36 192 171 CONNECTOR, rect 250 3skt 1 row plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG37 192 168 CONNECTOR, rect 250 1 pin 1 row rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG39 092 670 CONNECTOR, rect univ 084 3P/S 1 row plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 167 SEAL, wire univ 3P/S 1 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 CB7 147 658 CIRCUIT BREAKER, man rest 1P 30A 250VAC screw (see Figure 12-1) 1. . . . . . . . . . .

101 CB8 115 427 CIRCUIT BREAKER, man reset 1P 25A 250VAC frict (see Figure 12-1) 1. . . . . . . . . . .

102 CB10 139 266 SUPPLEMENTARY PROTECTOR, man reset 1P 15A 250VAC. . . . . . . . . . .

(see Figure 12-1) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187 654 SEAL, wire univ 12p/s 3row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148 850 SOCKET, relay 5 pin (for CR3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 Figure 12-3 INVERTER ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 198 158 PANEL, generator right 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 ♦198 874 PANEL, generator right stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105 233088 Label, Danger Using A Generator Indoors Can Kill You In Minutes 1. . . . . . . . . . . . . . . . . . . . . . .

194 126 KIT, foam 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦ Optional

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

OM-492 Page 62

 Hardware is common and

not available unless listed.

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23
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Figure 12-2. Front Panel

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-2. Front Panel (Figure 12-1, Item 93)

1 198 049 UPRIGHT, base front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 +191 737 PANEL, front louver 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 170 391 CONN, circ ms protective cap 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 RC14, PC6 224 951 CIRCUIT CARD ASSY, connector/receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG13 115 091 CONNECTOR, rect mini 045 10skt 2 row plug (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . .

5 CB5,CB6 083 432 SUPPLEMENTARY PRO, man reset 1P 10A 250VAC frict 2. . . . . . . . . . . . . . . . . . . .

6 2T, 3T 172 661 BLOCK, stud connection 6 position 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 212 480 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 206 795 BOOT, circuit breaker clear hex nut 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 601 836 NUT, 250-20 .50hex .19H brs 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 PC10 148 608 CIRCUIT CARD ASSEMBLY, filter HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 134 201 STAND−OFF SUPPORT, pc card .312/.375w/post&lock .43 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 PLATE, lower (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 NAMEPLATE, upper (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 083 030 STUD, brs .250-20 x 1.750 w/hex collar 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 213 456 COVER, receptacle duplex dual gfci weather proof 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 209 056 COVER, receptacle w/ gasket 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 203 016 BOOT, circuit breaker 2 pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 119 014 LEVER, switch black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 021 385 BOOT, tgl switch lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-492 Page 63

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802 327-F

Item

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Part

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Quantity

Figure 12-2. Front Panel (Continued)

22 192 265 GAUGE, fuel elec switch w/o switchgage sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 145 247 METER, hour 12−24vdc 1.25 x 2.12 rect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 PL1, PL2, PL3 206 879 LIGHT, ind amber lens 12v snap−in mtg .500 mtg hol 1. . . . . . . . . . . . . . . . . . . . . . .

25 CT2 192 237 TRANSFORMER, current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 S6 021 467 SWITCH, tgl spst 3a 250v off−none−(on) spd term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 S1 176 606 SWITCH, ignition 4posn w/o handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 PC3 225 974 CIRCUIT CARD ASSEMBLY, front panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210 844 SHIELD, pcb protective anti static 6.338x11.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 RC1 182 954 RECEPTACLE, str 3p4w 50a 125/250V (single-phase) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

♦119 172 PLUG, str grd 3p4w 50a 125/250v *14−50p (for RC1) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 CB1 217 858 SUPPLEMENTARY PROTECTOR, man reset 2P 50A 240VAC 1. . . . . . . . . . . . . . . . . .

31 RC2, RC3 214 918 RECEPTACLE, str dx grd 2p3w 20a 125v *5−20r 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

GFCI-1, 2 ♦151 981 RECEPTACLE, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi 2. . . . . . . . . . . . . . . . . . . . . .

32 CB2,CB3 093 996 SUPPLEMENTARY PRO, man reset 1P 20A 250VAC frict 2. . . . . . . . . . . . . . . . . . .

33 RC4 007 469 RECEPTACLE, twlk grd 3P4W 30A 250V (3-phase) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦007 470 PLUG, tw lk grd 3p4w 30a 250v *l15−30p (For RC4) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 CB4 192 565 SUPPLEMENTARY PROTECTOR, man reset 3P 30A 250VAC 1. . . . . . . . . . . . . . . . . .

35 203 017 BOOT, circuit breaker 3 pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 174 991 KNOB, pointer 1.250dia x .250 ID w/spring clip 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 174 992 KNOB, pointer .820dia x .250 ID w/spring clip 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 PC9 181 261 CIRCUIT CARD ASSY, filter hf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 186 621 BOOT, generic output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 181 169 SPACER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 180 735 WASHER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦ Optional

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

OM-492 Page 64

34

35

 Hardware is common and

not available unless listed.

25

24

23

22

33

5

26

18

21

15

14

20

27

13

19

18

17

12

16

28

32

29

10

30

9

8

11

31

36

37

38

39

40

41

42

44

43

45
46
47

5

7

4

6

3

2

1

802 326-B

Figure 12-3. Inverter Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-3. Inverter Assembly (Figure 12-1, Item 103)

1 PC2 196 148 CIRCUIT CARD ASSEMBLY, interconnecting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 C3,C4,C5 192 935 CAPACITOR, elctlt 2700uf 450 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 C1 186 015 CAPACITOR, polyp film .34uf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 025 248 STAND-OFF, insul .250-20 x 1.2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 179 276 BUSHING, snap-in nyl 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 175 140 BRACKET, DI/DT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 181 197 GASKET, DI/DT rubber 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 L3,L4 175 482 COIL, DI/DT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 109 056 CORE, ferrite E 2.164 lg x 1.09 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 185 731 WINDTUNNEL, RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 189 755 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 191 568 FOOT, mtg unit 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 200 649 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 170 647 BUSHING, snap-in 1.312 ID 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 175 084 MOTOR, fan 24VDC 3000RPM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 SR1 179 629 KIT, diode power module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 PM1,PM2 180 110 KIT, transistor IGBT module 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 RT1,RT2 173 632 THERMISTOR, NTC 30K ohm at 25D C 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 173 631 HEAT SINK, power module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 175 192 HEAT SINK, rect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 175 255 INSULATOR, rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 +183 551 WINDTUNNEL, LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-492 Page 65

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-3. Inverter Assembly (Continued)

23 181 853 INSULATOR, screw 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 HD1 189 567 TRANSDUCER, current 400A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 D1,D2 179 630 KIT, diode ultra-fast recovery 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 R1,C6,C7 175 194 RESISTOR/CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 185 835 LABEL, warning electric shock 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 T1 173 811 TRANSFORMER, HF 230/460 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 L1 173 563 INDUCTOR, input 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 Z1 189 525 STABILIZER, output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 189 420 BRACKET, mtg capacitor/PC board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 PC1 212 691 CIRCUIT CARD ASSEMBLY, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 +213 412 WRAPPER, inverter chassis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 190 861 LABEL, electric shock and moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 200 590 COVER, ribbon access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 T2 189 481 TRANSFORMER, control 300VA 230VAC pri 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 172 731 HOLDER, fuse mintr .250 x 1.250 clip anti−pivot 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 F1 169 296 FUSE, mintr gl 25. amp 125 volt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 189 422 BRACKET, mtg transformer control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 SR2 035 704 RECTIFIER, integ bridge 40. amp 800v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 115 440 STAND-OFF, No. 6-32 x .687 lg 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 200 651 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 PC8 213 231 CIRCUIT CARD ASSEMBLY, voltage regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 PC7 203 130 CIRCUIT CARD ASSY, gen power (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F1 027660 FUSE, Mintr Cer 20. Amp 250 Volt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 153 403 BUSHING, snap-in nyl .750 ID 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 177 547 BUSHING, snap-in nyl ct-mount 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 CT1 175 199 TRANSFORMER, current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213 410 HARNESS, wiring unit (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC26 147 663 CONNECTOR, rect univ 084 15 p/s 3 row rectp lkg (service kit) 1. . . . . . . . . . . . . . . . . . . . . . .

RC25 116 045 CONNECTOR, rect univ 084 6p/s 3 row rcpt lkg (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

PLG24, PLG44 115 094 CONNECTOR, rect mini 045 4skt 2 row plug (service kit) 1. . . . . . . . . . . . . . . . . . . .

RC10, PLG31 168 071 CONNECTOR, rect univ 084 9P/S 3 row rcpt (service kit) 1. . . . . . . . . . . . . . . . . . . .

PLG2 115 091 CONNECTOR, rect mini 045 10skt 2 row plug (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG23 130 203 CONNECTOR, rect mini 045 12 skt 2 row plug (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . .

RC24 047 483 CONNECTOR, rect univ 084 15P/S 3 row rcpt (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG50 136 810 CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg (service kit) 1. . . . . . . . . . . . . . . . . .

PLG43 115 093 CONNECTOR, rect mini 045 6skit 2row plg cable lkg (service kit) 1. . . . . . . . . . . . . . . . . . . .

PLG21 115 092 CONNECTOR, rect mini 045 8skt 2row plug cable lkg (service kit) 1. . . . . . . . . . . . . . . . . . .

PLG22 131 204 CONNECTOR, rect mini 045 3skt 1row plug cable lkg (service kit) 1. . . . . . . . . . . . . . . . . . .

PLG9 183 046 CABLE, LEM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*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-492 Page 66

 Hardware is common and

not available unless listed.

8

7

6

1

2

Item

No.

Dia.

Mkgs.

Part

No.

3

4

5

9

10

11

Figure 12-4. Generator

Description

Figure 12-4. Generator Assembly (Figure 12-1, Item 30)

802 338-B

Quantity

1 217 046 ENDBELL (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 216 532 RING, tolerance 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 213 388 ROTOR, generator (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 181 143 BEARING, ball rdl sgl row .984 x 2.047 x .591 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 192 600 FAN, rotor gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 +212 957 STATOR, generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 159 918 BAFFLE, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 193 515 ADAPTER, engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 013 367 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 170 861 STUD, stl .375-16 x 17.375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 205 725 BRUSHHOLDER ASSY, generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*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-492 Page 67

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

Notes

TM-188 304 Page 2

Invision 354MP

Notes

Start Your Professional

Welding Career Now!

400 Trade Square East, Troy, Ohio 45373

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

Over 80,000 trained

since 1930!

Warranty Questions?

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

Your distributor also gives
you ...

Service

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

Support

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

Effective January 1, 2007

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

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

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

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

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

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

2. 3 Years — Parts and Labor

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

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

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

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

Electronic

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

Models)
* Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

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

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

4. 6 Months — Batteries

5. 90 Days — Parts

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

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets, Cables, and

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

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

1. Consumable components; such as contact tips,

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

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

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

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

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

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

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

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

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

miller_warr 2007−01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

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

and Parts)
Circuit Diagrams
Welding Process Handbooks

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

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01