OM-4435

2007−04

218 759K

Processes
Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging

Description

Engine Driven Welding Generator

Big Blue 400 CX
)

File: Engine Drive
Visit our website at

www.MillerWelds.com

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 parts list will then help you to decide the equipment manufacturer in exact part you may need to fix the problem. the U.S.A. to be registered to the ISO 9001:2000 Quality Warranty and service information for your System Standard. 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. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Manufacturer’s Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 − OPERATING CC WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Lift-Arct Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 − OPERATING CC/CV WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Front Panel Controls (See Section 7-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Description Of Front Panel Controls (See Section 7-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Lift-Arct Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 2 3 3 4 4 4 5 5 5 6 7 7 8 8 8 9 9 10 11 12 12 12 13 14 14 15 16 16 17 18 19 19 20 21 22 23 24 24 25 26 27 28 30 30 31 32 33 34

TABLE OF CONTENTS
SECTION 8 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. CC Model Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. CC/CV Model Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3. Caterpillar Customer Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6. Inspecting And Cleaning Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8. Adjusting Engine Speed On Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9. Adjusting Engine Speed On Models With Automatic Idle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12. Optional Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 35 35 35 36 36 37 38 38 39 40 40 41 42 43 44 45 47 50 54 54 55 56 57 64

r. European Contact: Mr. IEC 60974-1 Ed. 133/04. 92/31/EEC. 93/68/EEC Noise level of Welding Generators: 2000/14/EC CE Marking Directive: 93/68/EEC Standards Arc Welding Equipment − Part 1: Welding Power Sources. Appleton. Managing Director ITW Welding Products Italy S. 92/31/EEC. Spencer St. Italy Phone: 39(02)98290-1 Fax: 39(02)98290203 European Contact Signature: Declares that the product: Big Blue 400 CX Directives Low Voltage Directive: 73/23/EEC.1 2004-10 The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility. 91/368/EEC. 11. Via Privata Iseo 6/E 20098 San Giuliano Milanese. IEC 60034-1 Ed. 1635 W. WI 54914 USA Phone: (920) 734-9821 This information is provided for units with CE certification (see rating label on unit). 2005-07 Rotating Electrical Machines − Part 1: Rating and Performance. 3.Declaration of Conformity for European Community (CE) Products NOTE Manufacturer : Miller Electric Mg. Co.l. 2006/95/EC conforms to the following Directives and Standards: Electromagnetic compatibility Directives: 89/336/EEC. Danilo Fedolfi. IEC 60974-10. dec_rot_1/07 . 1. 2004-04 Rotating Electrical Machines − Part 5: Classification Of Degrees Of Protection Provided By Enclosure Of Rotating Electrical Machines (IP Code) IEC 60034-5 2001-06 Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements. 2004/108/EC Machinery Directives: 98/37/EEC. Ed.

Spencer St. The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility. Co. Noise Level of Welding Generators 7/2004 Sound Level Information Measured Sound Power Level: 96 dB Guaranteed Sound Power Level: 96 dB Sound power level requirements determined by the 30% duty cycle of 400 A. Danilo Fedolfi. Italy Phone: 39(02)98290-1 Fax: 39(02)98290203 Notified Body: AV Technology Limited AVTECH House Birdhall Lane Cheadle Heath Stockport. dec_rotsound_6/05 . 23 V Conforming assessment procedure 1 of Annex VI will be followed. 1635 W. Via Privata Iseo 6/E 20098 San Giuliano Milanese.r. European Contact: Mr. Appleton.Declaration of Conformity for European Community (CE) Products NOTE Manufacturer : Miller Electric Mg. Managing Director ITW Welding Products Italy S. WI 54914 USA Phone: (920) 734-9821 This information is provided for units with CE certification (see rating label on unit).l. Chesire SK30XU European Contact Signature: The Manufacturer Declares the: Conforms to Directive: Effective Date: Big Blue 400 CX 2000/14/EC.

2) a DC manual (stick) welder. Properly install and ground this equipment according to its Owner’s Manual and national. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK. Do not connect more than one electrode or work cable to any single weld output terminal. use remote output control if present on unit. FUMES AND GASES can be hazardous. When you see the symbol. ground it directly with a separate cable. Do not use AC output in damp areas. If ventilation is poor. do not work alone! Disconnect input power or stop engine before installing or servicing this equipment. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing. MOVING PARTS. state. hole-free insulating gloves and body protection. lead. drive roll housing. or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. warn others not to watch the arc. heavy cotton. away. The input power circuit and machine internal circuits are also live when power is on. Do not weld in locations near degreasing. ELECTRIC SHOCK can kill. In semiautomatic or automatic wire welding. and follow the related instructions to avoid the hazard. D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder. wire reel. operate. Wear protective clothing made from durable. 1-1. D Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts. consumables. If AC output is required. Y Marks a special safety message. D D D D D BUILDUP OF GAS can injure or kill.1 listed in Safety Standards). or if there is a danger of falling. or spraying operations. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Frequently inspect input power cord for damage or bare wiring — replace cord immediately if damaged — bare wiring can kill. Touching live electrical parts can cause fatal shocks or severe burns. Repair or replace damaged parts at once. Use AC output ONLY if required for the welding process. Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals. 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. . coatings. Welding produces fumes and gases. or wool) and foot protection. damaged. Maintain unit according to manual. attach proper grounding conductor first − double-check connections. on metal structures such as floors. Breathing these fumes and gases can be hazardous to your health. cleaners. and sparks.1 and Z87. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. When making input connections. 1-2. and while wearing an air-supplied respirator. when in cramped positions such as sitting. or lying. For these conditions. Do not breathe the fumes. Work in a confined space only if it is well ventilated. glare. and HOT PARTS hazards. or poorly spliced cables. and degreasers. wear an approved air-supplied respirator. Turn off all equipment when not in use. Consult symbols and related instructions below for necessary actions to avoid the hazards. use of a DC. D D D D D D D Do not touch live electrical parts. Arc Welding Hazards Y The symbols shown below are used throughout this manual to call attention to and identify possible hazards. Y During operation. gratings. and local codes. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. and all metal parts touching the welding wire are electrically live. Wear approved safety glasses with side shields under your helmet. Do not drape cables over your body. D D D D D Keep your head out of the fumes. The coatings and any metals containing these elements can give off toxic fumes if welded. Y Only qualified persons should install. if movement is confined. the wire. maintain. watch out. especially children. Be sure the breathing air is safe. and repair this unit. Read and follow all Safety Standards. undersized. ground.147 (see Safety Standards). D D D D OM-4435 Page 1 . D D D D D D D D ARC RAYS can burn eyes and skin. kneeling. The electrode and work circuit is electrically live whenever the output is on. 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. keep everybody. Incorrectly installed or improperly grounded equipment is a hazard. SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine. Use only well-maintained equipment. Lockout/tagout input power according to OSHA 29 CFR 1910. flame-resistant material (leather. Sparks fly off from the weld. Do not use worn. In most situations. D D D D D Wear a safety harness if working above floor level.SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. Wear dry. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. such as galvanized. not safety related. And. or scaffolds. unless the coating is removed from the weld area. constant voltage wire welder is recommended. cleaning. or while wearing an airsupplied respirator. If earth grounding of the workpiece is required. D D Shut off shielding gas supply when not in use. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. Always have a trained watchperson nearby. Use protective screens or barriers to protect others from flash. Means “Note”. or cadmium plated steel. or 3) an AC welder with reduced open-circuit voltage. Keep all panels and covers securely in place. the area is well ventilated. 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. Do not weld on coated metals. Do not touch electrode if you are in contact with the work. Always ventilate confined spaces or use approved air-supplied respirator. If inside. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. or another electrode from a different machine.

1 (see Safety Standards). wire brushing. from your person before doing any welding. heavy shirt. and tools away from moving parts. maintain them and associated parts in good condition. Sparks can fly off from the welding arc. unless they are properly prepared according to AWS F4. and fire hazards. D D D D D D Stop engine and let it cool off before checking or adding fuel. Watch for fire. Stop engine before installing or connecting unit. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. or guards when servicing is finished and before starting engine. sparks. can cause them to blow up. Noise from some processes or equipment can damage hearing.7 m) of the welding arc. Do not use welder to charge batteries or jump start vehicles. Accidental contact of electrode to metal objects can cause sparks. or pipes. Follow requirements in OSHA 1910. D D D D D D D D Remove all flammables within 35 ft (10. clean up before starting engine. and fittings designed for the specific application. MAGNETIC FIELDS can affect pacemakers. Always keep nozzle in contact with tank when fueling. hot workpiece. Remove any combustibles. floor. and arcs. Stop engine before disconnecting or connecting battery cables or servicing battery. open flames. and hot equipment can cause fires and burns. and grinding cause sparks and flying metal. Keep protective cap in place over valve except when cylinder is in use or connected for use. Do not use welder to thaw frozen pipes. Engine Hazards BATTERY EXPLOSION can BLIND. and keep a fire extinguisher nearby. Turn face away from valve outlet when opening cylinder valve. Since gas cylinders are normally part of the welding process. Observe correct polarity (+ and −) on batteries. Keep all doors. Reinstall doors. Do not weld on closed containers such as tanks. and a cap. insulated welding gloves and clothing to prevent burns. covers. Be aware that welding on a ceiling. Wearers should consult their doctor before going near arc welding. covers. Do not weld where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Use only correct shielding gas cylinders. drums. D D D D D D D NOISE can damage hearing. If damaged. Keep cylinders away from any welding or other electrical circuits. hair. Block flywheel so that it will not turn while working on generator components. bulkhead. D D D Do not touch hot parts bare handed. drums. possibly unknown paths and causing electric shock. explosion. correct procedures. D D D Do not touch hot engine parts. hoses. Shielding gas cylinders contain gas under high pressure. associated equipment. D D Do not overfill tank — allow room for fuel to expand. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Check and be sure the area is safe before doing any welding. D D D D 1-3. rubber gloves. use proper tools and/or wear heavy. Do not spill fuel. D D D D D D Always wear a face shield. a cylinder can explode. Never drape a welding torch over a gas cylinder. The flying sparks. covers. physical damage. gouging. disconnect negative (−) battery cable from battery. panels. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long. If this is not possible. Wear oil-free protective garments such as leather gloves. or partition can cause fire on the hidden side. Allow cooling period before working on equipment. loose clothing. such as a butane lighter or matches. CYLINDERS can explode if damaged. FUEL can cause fire or explosion. sparks. Do not allow tools to cause sparks when working on a battery. or pipes. high shoes. Never weld on a pressurized cylinder — explosion will result. remove spark plugs or injectors to keep engine from kicking back or starting. Never allow a welding electrode to touch any cylinder. D D D D D D D Keep away from fans. Read and follow instructions on compressed gas cylinders. chipping. tightly cover them with approved covers. Keep hands. Dispose of rags in a fireproof container. Have only qualified people remove doors. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Wear approved safety glasses with side shields even under your welding helmet.WELDING can cause fire or explosion. Do not add fuel while smoking or if unit is near any sparks or open flames. Use the right equipment. and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards. and sufficient number of persons to llift and move cylinders. Protect compressed gas cylinders from excessive heat. or spot welding operations. Welding on closed containers. Allow cooling period before maintaining. or fire. To prevent accidental starting during servicing. cuffless trousers. If fuel is spilled.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. Disconnect negative (−) cable first and connect it last. Wear protective gloves and clothing when working on a hot engine. As welds cool. Before working on generator. slag. HOT PARTS can cause severe burns. or guards for maintenance and troubleshooting as necessary. MOVING PARTS can cause injury. mechanical shocks. OM-4435 Page 2 . belts. and protective clothing when working on a battery. D Wear approved ear protection if noise level is high. they can throw off slag. and rotors. regulators. and guards closed and securely in place. HOT PARTS can cause severe burns. To handle hot parts. panels. be sure to treat them carefully. D D Welding. overheating. panels. such as tanks. D D Pacemaker wearers keep away. D D D D D FLYING METAL can injure eyes.

hand. READ INSTRUCTIONS. ENGINE EXHAUST GASES can kill. vent engine exhaust outside and away from any building air intakes. instead of radiator (unless told otherwise in maintenance section or engine manual). 1-4. Do not direct air stream toward self or others. 1-5. HOT PARTS can cause burns and injury. and there is no overflow tank. or ship PC boards. Operation. Do not exceed maximum lift eye weight rating (see Specifications). Watch for fire. Keep exhaust and exhaust pipes way from flammables. Reduce current or reduce duty cycle before starting to weld again. adding or changing attachments. Use only for cutting. and body protection. or near combustible surfaces or flammables. Properly install welding generator onto trailer according to instructions supplied with trailer. if present on unit. D D D Use lifting eye to lift unit and properly installed accessories only. Use only genuine Miller/Hobart replacement parts. STATIC (ESD) can damage PC boards. and tools. Additional Symbols For Installation. If used in a closed area. Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face. Let system cool down before touching or servicing. D D Do not cut or gouge near flammables. D D Use equipment outside in open. D D Put on grounded wrist strap BEFORE handling boards or parts. OM-4435 Page 3 . gouging. Use proper static-proof bags and boxes to store. D D D Read Owner’s Manual before using or servicing unit. Replace damaged battery. keep extinguisher nearby. Do not let low voltage and frequency caused by low engine speed damage electric motors. D D D Do not tip battery. checking is needed. D D Do not touch hot compressor or air system parts. follow the next two statements.STEAM AND HOT COOLANT can burn. OVERHEATING can damage motors. D D D Turn off or unplug equipment before starting or stopping engine. TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury. D D Do not let engine exhaust sparks cause fire. D Sparks can cause fires — keep flammables away. ENGINE HEAT can cause fire. Flush eyes and skin immediately with water. Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable. Always check coolant level at overflow tank. Wear safety glasses and gloves and put a rag over radiator cap. Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death. COMPRESSED AIR can cause injury. D Release air pressure from tools and system before servicing. be sure forks are long enough to extend beyond opposite side of unit. D D D Allow cooling period. If using lift forks to move unit. Stop engine and release air pressure before servicing. Use approved engine exhaust spark arrestor in required areas — see applicable codes. or opening compressor oil drain or oil fill cap. OVERUSE can cause OVERHEATING. FLYING SPARKS can cause injury. And Maintenance FALLING UNIT can cause injury. D D If possible. move. follow rated duty cycle. BATTERY ACID can BURN SKIN and EYES. well-ventilated areas. TILTING OF TRAILER can cause injury. over. D D Wear approved safety goggles. Lift and support unit only with proper equipment and correct procedures. D D D If the engine is warm. HOT METAL from air arc cutting and gouging can cause fire or explosion. D D Use tongue jack or blocks to support weight. D D Do not use compressed air for breathing. check coolant level when engine is cold to avoid scalding. Turn cap slightly and let pressure escape slowly before completely removing cap. D D Wear a face shield to protect eyes and face. EXHAUST SPARKS can cause fire. D D Do not locate unit on. Do not block or filter airflow to unit.

If interference still occurs. and computer-driven equipment such as robots. stop using the equipment at once. Be sure this welding machine is installed and grounded according to this manual. National Electrical Code. such as on the floor. keep weld cables as short as possible. NFPA Standard 51B. 2.cganet.F. the user must take extra measures such as moving the welding machine. . 5. California Proposition 65 Warnings Y Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and.O. and down low. VA 22202-4102 (phone: 703-412-0900.nfpa. Until the final conclusions of the research are reached. from Compressed Gas Association. Principal Safety Standards Safety in Welding. Have only qualified persons familiar with electronic equipment perform this installation. Cutting. Quincy. For Gasoline Engines: Y Engine exhaust contains chemicals known to the State of California to cause cancer. as it flows through welding cables. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manuals.1. 1735 Jefferson Davis Highway. For Diesel Engines: Y Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer. website: www. close together. Quincy.O. Pittsburgh. computers. cancer. Subpart J. If cleared by your doctor. using shielded cables. chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. and Other Hot Work.” However. 11 West 42nd Street. 1-8. CSA Standard W117. Arrange cables to one side and away from the operator. from Global Engineering Documents (phone: 1-877-413-5184.READ INSTRUCTIONS. Standard for Fire Prevention During Welding. Wash hands after handling.org). safety services. If notified by the FCC about interference. Suite 1004. and Part 1926.) can interfere with radio navigation. 178 Rexdale Boulevard. terminals and related accessories contain lead and lead compounds. Box 9101. Part 1910. Superintendent of Documents. is 312-353-2220. Do not coil or drape cables around your body. ANSI Standard Z49.nfpa. Keep high-frequency source doors and panels tightly shut. sparky.S. studies are still going forth and evidence continues to be examined. and other reproductive harm. RADIATION can cause interference. you may wish to minimize your exposure to electromagnetic fields when welding or cutting. Practice For Occupational And Educational Eye And Face Protection. Be sure all equipment in the welding area is electromagnetically compatible. 1-7. and communications equipment. birth defects.1. NFPA Standard 70. website: www. from Global Engineering Documents (phone: 1-877-413-5184. Government Printing Office.ihs. computers. Box 371954. D H.osha. Arlington. Locate welding operation 100 meters from any sensitive electronic equipment. Subpart Q. NY 10036–8002 (phone: 212-642-4900.com). in the committee’s judgment. Chicago. Connect work clamp to workpiece as close to the weld as possible. P. However. keep spark gaps at correct setting.O. To reduce possible interference. 4. Box 9101. Code for Safety in Welding and Cutting. or other reproductive harm. birth defects. D D Use only genuine MILLER/Hobart replacement parts. and Allied Processes. 1-6. OM-4435 Page 4 To reduce magnetic fields in the workplace. P.org and www. (California Health & Safety Code Section 25249.global.org. website: www.com).global. a special blue ribbon committee of the National Research Council concluded that: “The body of evidence.) Y Battery posts. website: www. from National Fire Protection Association.com). will cause electromagnetic fields. Keep welding power source and cables as far away from operator as practical. About Pacemakers: Pacemaker wearers consult your doctor before welding or going near welding operations. 1 Battery March Park. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. use the following procedures: 1.org). Title 29. PA 15250 (there are 10 Regional Offices—phone for Region 5.1. OSHA.gov). D Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors.ansi. CGA Pamphlet P-1. Canada M9W 1R3 (phone: 800-463-6727 or in Toronto 416-747-4044. website: www. MA 02269-9101 (phone: 617-770-3000. There has been and still is some concern about such fields. Code of Federal Regulations (CFR). from Canadian Standards Association. website: www. 1 Battery March Park. and use grounding and shielding to minimize the possibility of interference. Ontario. D D D D ARC WELDING can cause interference. from U. Rexdale. P. has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard. American Welding Society Standard AWS F4. 3.csa-international. in some cases.5 et seq.org). from National Fire Protection Association. D D D D D D High-frequency (H.2. website: www. MA 02269-9101 (phone: 617-770-3000. Standards Sales. New York. Cutting. from American National Standards Institute. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping. Have the installation regularly checked and maintained. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current. website: www. using line filters. or shielding the work area. then following the above procedures is recommended. after examining more than 500 studies spanning 17 years of research. Keep cables close together by twisting or taping them. ANSI Standard Z87.F.ihs. Safe Handling of Compressed Gases in Cylinders. Occupational Safety and Health Standards for General Industry.

n’est pas relatif à la sécurité. 2) un poste à souder manuel (électrode enrobée) DC. Et. sur des structures métalliques au sol. de nettoyage ou de pulvérisation. 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. Signifie NOTA . Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910. Maintenir solidement en place tous les panneaux et capots. Demander toujours à un surveillant dûment formé de se tenir à proximité. Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage. 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 soudage génère des fumées et des gaz. tenir toute personne à l’écart et plus particulièrement les enfants. le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. et en portant un respirateur à alimentation d’air. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme: les endroits humides ou lorsque l’on porte des vêtements mouillés. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. D Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants. grillages et échafaudages. Réparer ou remplacer sur-le-champ les pièces endommagées. Des matériels mal installés ou mal mis à la terre présentent un danger. 2-1. 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. le fil. Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir. un poste courant continu de type CV est recommandé. Le circuit d’entrée et les circuits internes de l’appareil sont également sous tension à ce moment-là. Ne pas souder des métaux munis d’un revêtement. 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 . les revêtements. Si la pièce soudée doit être mise à la terre. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et les instructions du fabricant concernant les métaux.1 et Z87. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES. LES FUMÉES ET LES GAZ peuvent être dangereux. Porter des gants et des vêtements de protection secs ne comportant pas de trous. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. coton lourd ou laine) et des bottes de protection. tels que l’acier galvanisé. Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. les nettoyants et les dégraisseurs. . 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. l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées. Lorsque vous voyez un symbole. Veuillez lire et respecter toutes ces normes de sécurité. En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions. Porter des lunettes de sécurité avec écrans latéraux même sous votre casque. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. D D D D D Eloigner votre tête des fumées. Ne pas enrouler les câbles autour du corps. endommagés. le faire directement avec un câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour. Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée. plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure. 3) un poste à souder manuel AC avec tension à vide réduite. Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire. N’utiliser qu’un matériel en bon état. D D D D D D D D D D LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Leur inhalation peut être dangereux pour votre santé. Ne pas se servir de source électrique à courant électrique dans les zones humides. En soudage semi-automatique ou automatique. Si la ventilation est médiocre. 2-2. ne pas travailler seul! Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation. Dans la plupart des cas. À l’intérieur. ou quand il y a un risque important de contact accidentel avec la pièce ou le sol. Ne pas utiliser des câbles usés. D D D D D LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. L’installation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants. l’utilisation. provinciaux et municipaux. Mettre l’appareil hors tension quand on ne l’utilise pas. dans les endroits confinés ou là où on risque de tomber. le dévidoir. Au cours de l’utilisation. OM-4435 Page 5 . Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande. aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux. Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. à la réparation ou à l’entretien de l’appareil. Y Identifie un message de sécurité particulier. prévenir toute personne sur les lieux de ne pas regarder l’arc. D Fermer l’alimentation du gaz protecteur en cas de non utilisation. D D D D D D D Ne jamais toucher les pièces électriques sous tension.147 (voir normes de sécurité). à genoux et allongées. Des étincelles sont projetées pendant le soudage. le plus près possible de la soudure. que l’endroit soit bien ventilé. S’assurer que l’air de respiration ne présente aucun danger. Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. 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).1 énuméré dans les normes de sécurité). les consommables. porter un respirateur anti-vapeurs approuvé. D D D D Y Y Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation. dans des positions assises. Entretenir l’appareil conformément à ce manuel. UN CHOC ÉLECTRIQUE peut tuer. D D D D Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage (voir ANSI Z49.SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 3/05 Y Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. se servir de la fonction de télécommande si l’appareil en est équipé. la terre ou une électrode provenant d’une autre machine. Ne pas toucher l’électrode quand on est en contact avec la pièce. de grosseur insuffisante ou mal épissés. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles . soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Dangers relatifs au soudage à l’arc Y Les symboles présentés ci-après sont utilisés tout au long du présent manuel pour attirer votre attention et identifier les risques de danger. Ne pas respirer les fumées. Porter un harnais de sécurité quand on travaille en hauteur.

s’il y a lieu. d’étincelles et d’incendie. les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles. de gougeage ou de soudage par points. D Lire et suivre les instructions sur les bouteilles de gaz comprimé. D D LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des brûlures. Ne pas approcher les mains. des travaux d’entretien et de dépannage. Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc. Avant de commencer le soudage. Si des BOUTEILLES sont endommagées. des gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie. Avant de souder. Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide. une chemise en matériau lourd. Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie. une explosion. sauf en cas d’utilisation ou de branchement de la bouteille. D D D D D DES PARTICULES VOLANTES peuvent blesser les yeux. Seules des personnes qualifiées sont autorisées à enlever les portes. les maintenir ainsi que les éléments associés en bon état. D Toujours porter une protection faciale. D Ne pas approcher les mains des ventilateurs. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles. se en fil de fer. Suivre les recommandations dans OSHA 1910. Prévoir une période de refroidissement avant de travailler à l’équipement. tuyaux et raccords convenables pour cette application spécifique. recouvrements ou dispositifs de protection pour effectuer. D Ne jamais placer une torche de soudage sur une bouteille à gaz. vêtements lâches et outils des organes mobiles. D D D D D Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie. La projection d’étincelles. régulateurs. Ne pas toucher à mains nues les parties chaudes. et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur). Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir. D Protéger les bouteilles de gaz comprimé d’une chaleur excessive. des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. le passage de la pièce à la bros- 2-3. Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs. vérifier et s’assurer que l’endroit ne présente pas de danger. LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion. des pantalons sans revers. Si une bouteille est endommagée. à moins qu’ils n’aient été préparés correctement conformément à AWS F4. En cas de non utilisation. Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables. D Ne jamais souder une bouteille pressurisée − risque d’explosion.1 (voir les normes de sécurité).LE SOUDAGE peut provoquer un incendie ou une explosion. Laisser l’ensemble se refroidir avant d’effectuer la maintenance. Pour empêcher tout démarrage accidentel pendant les travaux d’entretien. retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes. Faire attention de ne pas renverser de carburant. Maintenir fermés et fixement en place les portes. D D DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.252(a)(2)(iv) et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. Le bruit des processus et des équipements peut affecter l’ouïe. Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud. du laitier. Le soudage effectué sur des conteneurs fermés tels que des réservoirs. les manipuler avec précaution. Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie. elles pourront exploser. D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. Ne pas toucher aux pièces chaudes. Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue. Ne pas faire le plein de carburant à ras bord. prévoir de l’espace pour son expansion. D LE BRUIT peut affecter l’ouïe. courroies et autres pièces en mouvement. D D D D DES PIECES CHAUDES peuvent provoquer des brûlures et blessures. Le soudage effectué sur un plafond. un surchauffement ou un incendie. et le meulage génèrent des étincelles et des particules métalliques volantes. Le rebrancher en dernier lieu. panneaux. Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. tambours ou des conduites peut provoquer leur éclatement. D Porter des protections approuvés pour les oreilles si le niveau sonore est trop élevé. des chaussures hautes et un couvre chef. D Maintenir le chapeau de protection sur la soupape. D Le soudage. des flammes ouvertes. l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécurité. Dangers existant en relation avec le moteur L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. cheveux. D Utiliser seulement des bouteilles de gaz protecteur. 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. déposer les bougies ou injecteurs pour éviter la mise en route accidentelle du moteur. D D D D Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein. des dommages physiques. D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. 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. D Utiliser les équipements corrects. D D D D D D D D D Déplacer toutes les substances inflammables à une distance de 10. Avant d’intervenir. paroi ou séparation peut déclencher un incendie de l’autre côté. OM-4435 Page 6 . Toujours vérifier le niveau de liquide de refroidissement dans le vase d’expansion (si présent).7 m de l’arc de soudage. Des étincelles peuvent être projetées de l’arc de soudure. Pendant la période de refroidissement des soudures. Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. Ne pas toucher les parties chaudes du moteur. ou conduites. tambours. DES ORGANES MOBILES peuvent provoquer des blessures. des étincelles et des arcs. restez à distance. Porter des gants et des vêtements de protection pour travailler sur un moteur chaud. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques. D Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter de se brûler. Débrancher le câble négatif (–) en premier lieu. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. D D Porteurs de stimulateur cardiaque. utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. Nettoyer tout carburant renversé avant de faire démarrer le moteur. D Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. Jeter les chiffons dans un récipient ignifuge. l’écaillement. enlever la baguette d’électrode du porte-électrode ou couper le fil à la pointe de contact. Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le générateur. Observer la polarité correcte (+ et −) sur les batteries. D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille. recouvrements et dispositifs de protection. panneaux. Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués. plancher. des chocs mécaniques. D D D D D D D Arrêter le moteur avant d’installer ou brancher l’appareil. débrancher le câble négatif (−) de batterie de la borne. D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser. elle peut exploser. elles risquent de projeter du laitier.

Tenir à distance les produits inflammables de l’échappement. au-dessus ou à proximité de surfaces inflammables. D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. 2-5. Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant. LA CHALEUR DU MOTEUR peut provoquer un incendie. D D Ne pas utiliser l’air comprimé pour respirer. Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles. L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT. s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. D LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie. D Utiliser uniquement des pièces de rechange Miller/Hobart. Ne pas obstruer les passages d’air du poste. Les étincelles risquent de causer un incendie − éloigner toute substance inflammable. Ne pas diriger le jet d’air vers d’autres ou soi-même. LES ÉTINCELLES VOLANTES risquent de provoquer des blessures. des mains et du corps. Ne pas couper ou gouger à proximité de produits inflammables. Utiliser les supports de la remorque ou des blocs pour soutenir le poids. D D Porter des lunettes de sécurité approuvées. 2-4. D LIRE LES INSTRUCTIONS. D D D Laisser l’équipement refroidir . Ne pas toucher le compresseur ou d’autres éléments du circuit air comprimé chauds. Utiliser l’air comprimé seulement pour le coupage. Dangers liés à l’air comprimé RESPIRER L’AIR COMPRIMÉ peut provoquer des blessures graves ou causer la mort. Remplacer une batterie endommagée. D Surveillez et garder un extincteur à proximité. Ne pas dépasser le poids nominal maximal de l’œilleton (voir les spécifications). Ne lever et ne soutenir l’appareil qu’avec de l’équipement approprié et en suivant les procédures adéquates. Rincer immédiatement les yeux et la peau à l’eau. s’il y a lieu. D D DES PIECES CHAUDES peuvent provoquer des brûlures et blessures. D LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Ne pas placer l’appareil sur. D Utiliser un œilleton de levage pour lever l’appareil et les accessoires correctement installés. Utiliser des pochettes et des boîtes antistatiques pour stocker. Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la maintenance. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. LE SURCHAUFFEMENT peut endommager le moteur électrique. L’AIR COMPRIMÉ peut provoquer des blessures. D D LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. D Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un incendie ou une explosion. D Fermer l’alimentation du gaz protecteur en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. opérer comme suivant. UNE REMORQUE QUI BASCULE peut entraîner des blessures. D D Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Lisez le manuel d’instructions avant l’utilisation ou la maintenance de l’appareil. D D Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur. Mettre des lunettes de sécurité et des gants. D D D Ne pas renverser la batterie. placer un torchon sur le bouchon du radiateur. D Arrêter le moteur et relâcher la pression avant d’effectuer la maintenance. respecter le facteur de marche nominal. Dangers supplémentaires en relation avec l’installation.D D D Si le moteur est chaud et que le liquide doit être vérifié. déplacer ou expédier des cartes de circuits imprimes. D D D Porter un écran facial pour protéger le visage et les yeux. L’AIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provoquer des blessures. Utiliser uniquement un pare-étincelles approuvé − voir codes en vigueur. Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz. Réduire le courant ou le facteur de marche avant de poursuivre le soudage. avant de changer ou de rajouter des éléments ou avant d’ouvrir la purge ou le bouchon de remplissage d’huile. D D Empêcher les étincelles d’échappement du moteur de provoquer un incendie. L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et sur la PEAU. D Relâcher la pression d’air de l’outillage ou du système avant d’effectuer la maintenance. gougeage et les outils pneumatiques. D D En utilisant des fourches de levage pour déplacer l’unité. OM-4435 Page 7 . le fonctionnement et la maintenance LA CHUTE DE L’APPAREIL peut blesser. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage.

Box 9101. et les poser aussi bas que possible (ex. L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots. En attendant que les conclusions finales de la recherche soient établies. MA 02269-9101 (téléphone : 02269-9101 (téléphone : 617-770-3000. 3.F. Pour les moteurs diesel : Y 2-7.org). Code of Federal Regulations (CFR). Chicago.O. maintenir les câbles de soudage aussi courts que possible. Part 1910. des études sont toujours en cours et les preuves continuent à être examinées. l’utilisation de câbles blindés. Quincy. Principales normes de sécurité Safety in Welding. D D Utiliser seulement les pièces de rechange d’origine. Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184. 1 Battery March Park. après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans.F.) risque de provoquer des interférences. site Internet : www. 1004. site Internet : www. www. Ontario. Le rayonnement haute fréquence (H.csa-international.org). de U.org). Garder le poste de soudage et les câbles le plus loin possible de vous. de Compressed Gas Association. New York. des cancers. les bornes et autres accessoires contiennent du plomb et des composés à base de plomb. En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur médecin avant de souder ou d’approcher des opérations de soudage. Suite OSHA. Se laver les mains après manipulation. produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Y Proposition californienne 65 Avertissements Pour les moteurs à essence : Y 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. chapitre 25249.com). 2.O.2. Subpart Q.1 de Global Engineering Documents (téléphone : 1-877-413-5184. il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage. 5. Superintendent : www. Boulevard. NFPA Standard 51B. Arlington. est 312-353-2220. Si le médecin approuve.800-463-6727 ou à Toronto 416-747-4044. Box 371954. site Internet : www. CSA Standard W117. Cutting. les services de sécurité et les ordinateurs. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping. VA 22202-4102 (téléphone : 703-412-0900.S. and Allied Processes. n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine ». il est recommandé de suivre les procédures précédentes. arrêter immédiatement l’appareil. Le courant de soudage. Safe Handling of Compressed Gases in Cylinders.osha. and Other Hot Association. Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence. Disposer les câbles d’un côté et à distance de l’opérateur.global. site Canadian Standards Association.global. causera des champs électromagnétiques.LIRE LES INSTRUCTIONS. 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.cganet.com).) peut provoquer des interférences avec les équipements de radio−navigation et de communication.nfpa. Subpart J.O. ANSI Standard Z49. P. 1735 Jefferson Davis Highway. L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. D D D D D D D D D D D 2-6.1.1. Information EMF procédures suivantes : 1.ihs. Pittsburgh. 617-770-3000. of Documents. Pour réduire les champs magnétiques sur le poste de travail. NY 10036-8002 (téléphone : 212-642-4900. LE RAYONNEMENT HAUTE FRÉQUENCE (H.gov).ansi. 11 West 42nd Street. 1 Battery March Park. de National Fire Protection Standard for Fire Prevention During Welding. Effectuer régulièrement le contrôle et l’entretien de l’installation. Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement. American Welding Society Standard AWS F4.nfpa. D LE SOUDAGE À L’ARC risque de provoquer des interférences. Practice For Occupational And Educational Eye And Face Protection. Maintenir les câbles ensemble en les tordant ou en les enveloppant. de régionaux−−le téléphone de la région 5. de National Fire Protection Association. site In. and Part 1926. site Internet Title 29.com). P. Connecter la pince sur la pièce aussi près que possible de la soudure. Cependant. Pour réduire la possibilité d’interférence. 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 précédentes. un comité spécial ruban bleu du National Research Council a conclu : « L’accumulation de preuves. 2-8. Cutting. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.ihs. appliquer les OM-4435 Page 8 . pendant son passage dans les câbles de soudage. Rexdale. de American National Standards Institute. 4. Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. dans certains cas. il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste.5 et suivants) Les batteries. suivant le jugement du comité. les grouper. par terre). Si le FCC signale des interférences. P. Box 9101. Il y a eu et il y a encore un certain souci à propos de tels champs. site Internet : www. PA 15250 (il y a 10 bureaux Code for Safety in Welding and Cutting. Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). Toutefois. Government Printing Office. National Electrical Code. Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques.org). CGA Pamphlet P-1. ANSI Standard Z87. Ne pas courber pas et ne pas entourer pas les câbles autour de votre corps. Y 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. 178 Rexdale Internet : www. NFPA Standard 70. maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles. (Code de santé et de sécurité de Californie. site Internet : ternet : www. MA Work. Quincy. Standards Sales. Occupational Safety and Health Standards for General Industry. l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

Warning! Watch Out! There are possible hazards as shown by the symbols. Use Diesel Fuel only. Read the safety rules at the beginning of this manual. CD/SE.SECTION 3 − DEFINITIONS 3-1. change the oil and oil filter. Read Owner’s Manual. OM-4435 Page 9 . Follow instructions to install muffler. Warning Label Definitions S-177 571 1 1 + + DIESEL 2 3 4 2 3 4 5 6 5 0 − 50 h Std. Read Owner’s Manual. 200A 0 − 200A 7 Remove unit from shipping crate. Follow instructions to activate battery. API CD-MIL L 2104D. During the first 50 hours of operation. keep welding load above 200 amperes. CD/SF 3/96 Notes Work like a Pro! Pros weld and cut safely. After the first 50 hours of operation. Add oil if necessary. and fill fuel tank. 50 h Std. Check oil level. Read labels on unit. Do not weld below 200 amperes of output. Leave room for expansion. Remove Owner’s Manual from unit.

Manufacturer’s Rating Label OM-4435 Page 10 .3-2.

3-3. Symbols And Definitions NOTE Stop Engine Some symbols are found only on CE products. Weld/ Power) Slow (Idle) Start Engine Starting Aid (Preheat) Battery (Engine) Engine Oil Pressure Engine Oil Check Injectors/ Pump Check Valve Clearance Fuel Protective Earth (Ground) Positive Negative Certified/Trained Mechanic Welding Arc A Amperes V Volts Panel/Local Remote Engine Air Temperature Or Engine Temperature Constant Current (CC) Output Alternating Current Stick (SMAW) Welding MIG (GMAW) Welding TIG (GTAW) Welding Time h Hours s 3 G Seconds 1 Single Phase 3 Three Phase Read Operator’s Manual Circuit Protection Engine-Driven. Fast (Run. Three-Phase Alternator With Rectifier Conventional Load Voltage Do Not Switch While Welding Electrode Connection Work Connection Hz Hertz X n1 Duty Cycle U0 n0 Rated No Load Voltage (Average) U2 I n I2 Rated Load Speed Rated Idle Speed Rated No Load Speed Current Rated Welding Current Contactor On Arc Force (Dig) Lift-Arc TIG Remote Foot Control TIG (GTAW) OM-4435 Page 11 .

5 gal (43. Depth A B C D E F G H Weight No fuel: 1100 lb (499 kg) w/ fuel: 1199 lb (544 kg) Lifting Eye Weight Rating: 1500 lb (680 kg) Maximum OM-4435 Page 12 . 26. Dimensions. brackets turned out) 56 in (1422 mm) 56 in (1422 mm) 54 in (1372 mm) 52 in in (1321 mm) 2 in (51 mm) 26 in (660 mm) 7/8 in (22 mm) 27-3/4 in (705 mm) 9/16 in (14 mm) Dia. 32 Volts DC 60% Duty Cycle 250 A. Weld. kVA/kW 91/46 A. 10 kVA/kW. Weights.5 L) CV/DC Flux Core 14 − 40 V 4-2.5 kVA/kW. brackets turned in) 28-3/4 in (730 mm) (mtg. 29 Volts DC 60% Duty Cycle 250 A. 60 Hz Receptacles 110/55 V AC Receptacles 5. 4 Holes H Front Panel End D E F 20° 20° 30° 30° A B C G Width Y Do not exceed tilt angles or engine could be damaged or unit could tip.SECTION 4 − SPECIFICATIONS 4-1. 30 Volts DC 100% Duty cycle 300 A. 50/20 A Caterpillar 3013C Water−Cooled Three−Cylinder 21. 50/100 A 220/110 V AC Receptacles 11 kVA/kW. Y Do not move or operate unit where it could tip. A 110/220 V AC.5 Volts DC 100% Duty cycle 73 Generator Single-Phase. Power. And Engine Specifications Welding Mode Weld Output Range Rated Welding Output Maximum OpenCircuit Voltage Auxiliary Power Rating Engine Fuel Capacity CC/DC 20 − 410 A 300 A.7 HP Diesel Engine 11. And Operating Angles Dimensions Height 32 in (813 mm) 35-3/4 in (908 mm) (to top of lift eye) 26-1/4 in (667 mm) (mtg.

TIG Mode 100 80 DC VOLTS 60 40 20 0 0 MIN 100 200 300 300 400 MAX 500 222 108 / 221 800 / 217 518 DC AMPERES OM-4435 Page 13 . MIG Mode 100 80 DC VOLTS 60 40 20 0 0 100 MAX MIN 200 300 DC AMPERES 400 500 C. B. Stick Mode 100 90 80 70 DC VOLTS 60 50 40 30 20 10 0 0 100 200 300 DC AMPERES 400 500 MIN 300 MAX The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator.4-3. Curves of all other settings fall between the curves shown. Volt-Ampere Curves A.

25 1.50 0. Y Exceeding duty cycle can damage unit and void warranty. 1.75 0.00 0 IDLE 50 100 150 200 250 300 350 400 DC WELD AMPERES AT 100% DUTY CYCLE 217 509 4-5.00 0. GAL/HR.25 0.00 1. Continuous Welding 1000 800 WELD AMPERES 600 500 400 300 250 200 150 100 CV CC 10 15 20 25 30 40 50 60 80 100 % DUTY CYCLE 217 515 OM-4435 Page 14 .75 U.50 1.4-4. Duty Cycle And Overheating 100% Duty Cycle At 250 Amperes Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. 2.S. Fuel Consumption The curve shows typical fuel use under weld or power loads.

25 in) 5/16 in (.125 in) 3/16 in (.4-6.063 in) 14 Gauge (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) OM-4435 Page 15 .188 in) 1/4 in (.037 in) 18 Gauge (. AC Generator Power Curve The ac power curve shows the generator power in amperes.031 in) 20 Gauge (. 240 200 AC VOLTS 160 120 80 40 0 120 100 80 60 40 20 0 0 0 20 10 40 60 80 100 120 AC AMPERES IN 110V MODE 20 30 40 50 60 AC AMPERES IN 220V MODE 140 70 220 346−B Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.050 in) 16 Gauge (.025 in) 22 Gauge (.078 in) 1/8 in (.

See Section 4-2 for lifting eye rating. Location/Airflow Clearance Movement . and some running gears insulate the welding generator from the vehicle frame. shipping skids. Y Do not install unit where air flow is restricted or engine may overheat.SECTION 5 − INSTALLATION 5-1. use GFCI-protected extension cord. Grounding: 1 OR OR 2 3 Equipment Grounding Terminal (On Front Panel) Grounding Cable (Not Supplied) Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame. Use #10 AWG or larger insulated copper wire. Installing Welding Generator Y Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. OR Y If unit does not have GFCI receptacles. install3 8/06 − Ref. 800 652 / Ref. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown. 3 Y Bed liners. Y Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. 800 477-A / 803 274 / 804 712 OM-4435 Page 16 . 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) Grounding GND/PE 1 2 Electrically bond generator frame to vehicle frame by metal-to-metal contact. See Section 5-2 for mounting information. .

Use cross-supports to adequately support unit and prevent damage to base. To Weld Unit In Place: Weld unit to truck or trailer only at the four mounting brackets. Mounting Surface: OR 1 2 Cross-Supports Mounting Brackets (Supplied) Supporting The Unit 2 1 Inadequate support. Mounting Welding Generator Y Do not weld on base. Y Do not mount unit by supporting the base only at the four mounting brackets. 2 Welding Unit In Place Bolting Unit In Place 2 3 4 Tools Needed: 9/16 in install3 8/06 803 274 / 200 864-A / Ref 804 444-A OM-4435 Page 17 .5-2. Reverse brackets and reattach to base with original hardware. 1 To Bolt Unit In Place: Remove hardware securing the four mounting brackets to the base. Mount unit to truck or trailer with 1/2 in (12 mm) or larger hardware (not supplied). Mount unit on flat surface or use cross-supports to support base. CC model shown. Secure unit with mounting brackets. Using Mounting Brackets . 3 4 1/2 in Bolt And Washer (Minimum − Not Supplied) 3/8-16 x 1 in Screws (Supplied) Y Do not use flexible mounts. Welding on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down.

OM-4435 Page 18 . Installing Exhaust Pipe Y Stop engine and let cool. Tools Needed: 1/2 in 803 582−F / Ref.5-3. Read the safety rules at the beginning of this manual. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. . 226 386 Notes Work like a Pro! Pros weld and cut safely.

5-4. Activating The Dry Charge Battery (If Applicable)
Y Always wear a face shield, rubber gloves and protective clothing when working on a battery. Remove battery from unit. 5 6 7 Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well

3

2 1

Fill each cell with electrolyte to bottom of well (maximum). Y Do not overfill battery cells. Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps. 8 Battery Charger Y Read and follow all instructions supplied with battery charger. Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 amperes. Disconnect charging cables and install battery. 4

. When electrolyte

is low, add only distilled water to cells to maintain proper level.

5 A For 30 Minutes OR

+ −

Tools Needed:

30 A For 12 Minutes
drybatt1 6/05 − S-0886

5-5. Connecting The Battery . Close door after connecting battery.

Y Connect Negative (−) Cable Last.

+ −

Tools Needed: 1/2 in

Ref. 804 009-C / Ref. 226 386 / S-0756-C

OM-4435 Page 19

5-6. Engine Prestart Checks

Check radiator coolant level when fluid is low in recovery tank. Full Full

Diesel Capacity: 6 qt (5.7 L)

Coolant Recovery Tank

Hot Full Cold Full

Full

Ref. 804 009−C

. Check all engine fluids daily. Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high.
down switch. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level. Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe during run-in, see Section 11. Fuel Y Do not use gasoline. Gasoline will damage engine. The unit is shipped with enough fuel to prevent air from entering fuel system. Add fresh diesel fuel before starting (see engine maintenance label for fuel specifications). Leave filler neck empty to allow room for expansion. OM-4435 Page 20

Do not run out of fuel or air will enter fuel system and cause starting problems. See engine manual to bleed air from fuel system. Oil After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label). Coolant Check coolant level in radiator before starting unit the first time. If necessary, add coolant to radiator until coolant level is at bottom of filler neck. Check coolant level in recovery tank daily. If necessary, add coolant to recovery tank until coolant level is between Cold Full and Hot Full levels. If recovery tank coolant level was low, also check coolant level in radiator. Add coolant if level is below bottom of radiator filler neck. Unit is shipped with an engine coolant mixture of water and ethylene glycol base antifreeze rated to −34° F (−37° C). Add anti-

freeze to mixture if using the unit in temperatures below −34° F (−37° C). Keep radiator and air intake clean and free of dirt. Y Incorrect engine temperature can damage engine. Do not run engine without a properly working thermostat and radiator cap.

. This unit has a low oil pressure shut-

. To improve cold weather starting:
Use Preheat switch (see Section 6-1). Keep battery in good condition. Store battery in warm area. Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for fuel information. Use correct grade oil for cold weather (see Section 9-1).

5-7. Connecting To Weld Output Terminals

Stick and TIG Welding For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect electrode holder cable to Positive (+) terminal and work cable to Negative (−) terminal on left. For Direct Current Electrode Negative (DCEN), reverse cable connections. Use Process switch to select type of weld output (see Section 6-3).

MIG and FCAW Welding For MIG and FCAW welding Direct Current Electrode Positive (DCEP), connect wire feeder cable to Positive (+) terminal and work cable to Negative (−) terminal on left. Use Process switch to select type of weld output (see Section 6-3). For Direct Current Electrode Negative (DCEN), reverse cable connections.

Y Stop engine. 1 2 Work (−) Weld Output Terminal Positive (+) Weld Output Terminal(s)

. CC/CV model shown.

Y Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. 3 4 5 6 Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar

Remove supplied nut from weld output terminal. 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.

1

2

3

6

Do not place anything between weld cable terminal and copper bar.

4 5 Tools Needed: 3/4 in Correct Installation Incorrect Installation
Ref.804 009-C / Ref. 226 386 / 803 778-A

OM-4435 Page 21

5-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less Weld Output Terminals
Y Stop engine before connecting to weld output terminals. Y Do not use worn, damaged, undersized, or poorly spliced cables. 100 150 200 250 300 350 400 500
* This

150 ft (45 m)

200 ft (60 m)

250 ft (70 m)

300 ft (90 m)

350 ft 400 ft (105 m) (120 m)

Welding Amperes

10 − 60% Duty Cycle

60 − 100% Duty Cycle

10 − 100% Duty Cycle

4 (20) 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 2/0 (70)

4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 2/0 (70) 3/0 (95)

4 (20) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95) 4/0 (120)

3 (30) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120) 2 ea. 2/0 (2x70)

2 (35) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95)

1 (50) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120)

1/0 (60) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95)

1/0 (60) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95)

chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.
S-0007-F

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

Notes

OM-4435 Page 22

24 VOLTS AC B C REMOTE OUTPUT CONTROL D E F OR H GND NEUTRAL Ref 804 009-C K G *The remaining sockets are not used. Circuit common for 24 volt ac circuit. Contact closure to A completes 24 volt ac contactor control circuit. Chassis common. CC/CV model shown. OM-4435 Page 23 .5-9. DC input command signal: 0 to +10 volts from min. Output to remote control:+10 volts dc in MIG mode. Voltage feedback: 1 volt per 10 arc volts. Protected by supplementary protector CB8. Connecting To Remote 14 Receptacle RC14 . Notes Work like a Pro! Pros weld and cut safely. Current feedback: 1 volt per 100 amperes. Socket* A Socket Information 24 volts ac. to max. 0 to +10 volts dc in Stick or TIG mode. Read the safety rules at the beginning of this manual. Remote control circuit common. of remote control with Voltage/ Amperage Adjust control at max.

Front Panel Controls (See Section 6-2) 6 7 8 9 10 1 2 4 5 3 Stop 226 390−A / 804 009−C OM-4435 Page 24 .SECTION 6 − OPERATING CC WELDING GENERATOR 6-1.

the meters display Help 25 (see Section 9-12). 9 DC Voltmeter . Below 325 F (05 C): turn engine control switch to Auto position. . However. Voltmeter displays preset voltage (MIG welding) with contactor off. Weld Controls 6 Remote Control Receptacle Use receptacle to connect remote controls. With remote control connected. In Run position. turn Engine Control switch to Run or Auto (optional) position. If engine does not start. . the Engine Stop lever will not stop the engine if the engine can draw fuel-rich air from the surrounding atmosphere (oil refineries). 5 Engine Indicator Light Light goes on and engine stops if engine temperature exceeds 230° F (110° C) or engine oil pressure is below 10 psi (69 kPa). and actual output voltage with the contactor on. 2 Engine Control Switch Engine Gauges. Weld Meters (Optional) Use switch to start engine. Description Of Front Panel Controls (See Section 6-1) Engine Starting Controls 1 Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions following). If a remote device connected to Remote Receptacle RC14 is faulty or is disconnected. the front panel Voltage/Amperage control adjusts voltage and amperage. If no remote control is connected to the Remote receptacle. Turn V/A control until desired voltage is displayed on Voltmeter. . The Engine Stop lever shuts off the fuel supply. the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control (see Section 5-9). To Stop: turn Engine Control switch to Off position. To Start: Y Do not use ether. turn contactor off and turn Process/Contactor switch to Wire position. let engine come to a complete stop before attempting restart. 8 Voltage/Amperage Control With Process/Contactor switch in any Stick or TIG setting. With Process/Contactor switch in any Wire (MIG) position.2035 Y Do not run engine until trouble is fixed. weld output is determined by a combination of front panel and remote control voltage/amperage settings. To set amperage. When welding is finished. With Voltage/Amperage Adjust Switch in Remote position. And Lights 4 Fuel Gauge/Hourmeter Use gauge to check fuel level or total engine operating hours. use control to adjust voltage. and actual output amperage when welding. turn Process/Contactor switch to Stick or TIG position. Turn V/A control until desired amperage is displayed on Ammeter. and tools. Release Engine Control switch and Preheat switch when engine starts. control limits the remote amperage in Stick or TIG mode. use control to adjust amperage. Release Engine Control switch when engine starts. wire feeders.955 C). 7 Process/Contactor Switch See Section 6-3 for Process/Contactor switch information. OM-4435 Page 25 . Normal engine temperature is 180 . Voltmeter displays voltage at the weld output terminals. Turn Engine Control switch to Start. Push Preheat switch up for 60 seconds. engine runs at weld/power speed. Normal oil pressure is 30 . select engine speed (if unit has auto idle option). voltmeter displays weld voltage and then defaults to preset voltage. In Auto position (optional). Above 325 F (05 C): turn Engine Control switch to Start. engine runs at idle speed at no load and weld speed with load applied. When welding is finished.414 kPa). To check fuel level or engine hours when engine is not running. Meters. but has no effect in Wire (MIG) modes. 3 Engine Stop Lever Use lever to stop engine if Engine Control switch does not work. Clear fault by stopping and restarting the unit or by turning Process/Contactor switch to another position. and stop engine. F (82 . ammeter displays weld amperage and then defaults to preset amperage. Weld meters also work in combination to display troubleshooting help codes (see Section 9-12). 10 DC Ammeter Ammeter displays preset amperage (Stick and TIG only) when not welding.60 psi (207 . To set voltage. . When a remote control is connected to the Remote receptacle.6-2. but not necessarily the welding arc due to resistance of cable and connections.

1 Ref 804 444−A / Ref 226 390−A Process/Contactor Switch Settings Switch Setting Remote On/Off Switch Required −TIG HF Required Or Scratch Start Remote On/Off Switch Required − CV Feeder Using 24 Volt Remote Weld Terminals Always On − Wire Process GTAW With HF Unit. Air Carbon Arc (CAC-A) Cutting And Gouging TIG Lift-Arc (GTAW) Output On/Off Control At Remote 14 Receptacle Engine Auto Idle (Optional) Active At Remote 14 Receptacle Active Electrode Hot Active Weld Terminals Always On − Stick Weld Terminals Always On − TIG Lift-Arc OM-4435 Page 26 Electrode Hot Active Electrode Hot Active .6-3. Pulsing Device. Place switch in Weld Terminals Always On positions for weld output to be on whenever the engine is running. Use switch to select weld process and weld output on/off control (see table below). Or Remote Control Flux Core w/Constant Speed Feeder Flux Core w/Voltage Sensing Feeder Stick (SMAW). Process/Contactor Switch 1 Process/Contactor Switch Y Weld output terminals are energized when Process/Contactor switch is in a Weld Terminals Always On position and the engine is running. Place switch in Remote On/Off Switch Required positions to turn weld output on and off with a device connected to the Remote 14 receptacle. Use the Lift-Arc TIG mode for TIG (GTAW) welding using the Lift-Arc TIG starting procedure (see Section 6-4).

Normal open-circuit voltage is not present before tungsten electrode touches workpiece. only a low sensing voltage is present between electrode and workpiece. Read the safety rules at the beginning of this manual.6-4. Touch tungsten electrode to workpiece at weld start point. or to replace the scratch method. sticking. start arc as follows: 1 Lift-Arc Start Method 1 2 2 TIG Electrode Workpiece Turn gas on. This allows electrode to touch workpiece without overheating. Arc is formed when electrode is lifted. Lift-Arc™ Start Procedure Lift-Arc t TIG With Lift-Arct TIG selected. “Touch” 1−2 Seconds Do NOT Strike Like A Match! Notes Work like a Pro! Pros weld and cut safely. and slowly lift electrode. Hold electrode to workpiece for 1-2 seconds. or being contaminated. The solid-state output contactor does not energize until after electrode is touching workpiece. Application: Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted. OM-4435 Page 27 .

When a remote control is connected to the 1 Remote receptacle. Remote Voltage/Amperage Control 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-9). . When a device is connected to the Remote receptacle.226 390−A / Ref 804 444−A OM-4435 Page 28 .6-5. the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control. remote voltage/amperage control is always available regardless of the position of the Process/Contactor switch. Example: Combination Remote Amperage Control (FCAW) In Example: Process = Remote FCAW Min = 20 A DC Max = 205 A DC Max (205 A DC) Min (20 A DC) Connect Remote Control To Remote Receptacle RC14 Set Remote Process (Only If Remote On/Off Control Is Desired) Set V/A Control Mid-Range: About 205A Adjust Optional Remote Control Example: Combination Remote Amperage Control (TIG) In Example: Process =Remote TIG Min = 20 A DC Max = About 205 A DC Max (205 A DC) Min (20 A DC) Connect Remote Control To Remote Receptacle RC14 Set Remote Process (Only If Remote On/Off Control Is Desired) Set V/A Control Mid-Range: About 205 A Adjust Optional Remote Control 0774 / Ref.

Notes OM-4435 Page 29 .

SECTION 7 − OPERATING CC/CV WELDING GENERATOR 7-1. Front Panel Controls (See Section 7-2) 6 7 8 9 10 1 2 4 5 3 Stop 226 386-B / 804 009-C OM-4435 Page 30 .

To set voltage. but has no effect in Wire (MIG) modes. When welding is finished. control limits the remote amperage in Stick or TIG mode.60 psi (207 . weld output is determined by a combination of front panel and remote control voltage/amperage settings.955 C). Normal engine temperature is 180 . . However. Weld meters also work in combination to display troubleshooting help codes (see Section 9-12). . turn contactor off and turn Process/Contactor switch to Wire position. Description Of Front Panel Controls (See Section 7-1) Engine Starting Controls 1 Preheat Switch Use switch to energize starting aid for cold weather starting (see starting instructions following). With remote control connected. Voltmeter displays preset voltage (MIG welding) with contactor off. Turn V/A control until desired voltage is displayed on Voltmeter. the Engine Stop lever will not stop the engine if the engine can draw fuel-rich air from the surrounding atmosphere (oil refineries). and actual output voltage with the contactor on. The Engine Stop lever shuts off the fuel supply.414 kPa). 9 DC Voltmeter . Meters. . 2 Engine Control Switch Engine Gauges. wire feeders. Clear fault by stopping and restarting the unit or by turning Process/Contactor switch to another position. And Lights 4 Fuel Gauge/Hourmeter Use gauge to check fuel level or total engine operating hours. 7 Process/Contactor Switch See Section 6-3 for Process/Contactor switch information. 3 Engine Stop Lever Use lever to stop engine if Engine Control switch does not work. use control to adjust voltage. turn Engine Control switch to Run or Auto (optional) position. and tools. ammeter displays weld amperage and then defaults to preset amperage. use control to adjust amperage. but not necessarily the welding arc due to resistance of cable and connections.7-2. In Auto position (optional). engine runs at weld/power speed. When a remote control is connected to the Remote receptacle. With Voltage/Amperage Adjust Switch in Remote position. and stop engine. F (82 . To Start: Y Do not use ether. Release Engine Control switch and Preheat switch when engine starts. If no remote control is connected to the Remote receptacle. To Stop: turn Engine Control switch to Off position. Turn Engine Control switch to Start. the front panel Voltage/Amperage control adjusts voltage and amperage. With Process/Contactor switch in any Wire (MIG) position. 10 DC Ammeter Ammeter displays preset amperage (Stick and TIG only) when not welding. Voltmeter displays voltage at the weld output terminals. Above 325 F (05 C): turn Engine Control switch to Start. When welding is finished. Turn V/A control until desired amperage is displayed on Ammeter. and actual output amperage when welding. To set amperage. select engine speed (if unit has auto idle option). Normal oil pressure is 30 . If engine does not start. the meters display Help 25 (see Section 9-12). Release Engine Control switch when engine starts. the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control (see Section 5-9). turn Process/Contactor switch to Stick or TIG position. 8 Voltage/Amperage Control With Process/Contactor switch in any Stick or TIG setting. Weld Meters Use switch to start engine. Weld Controls 6 Remote Control Receptacle Use receptacle to connect remote controls. To check fuel level or engine hours when engine is not running. Below 325 F (05 C): turn engine control switch to Auto position. Push Preheat switch up for 60 seconds. let engine come to a complete stop before attempting restart. In Run position. engine runs at idle speed at no load and weld speed with load applied. If a remote device connected to Remote Receptacle RC14 is faulty or is disconnected.2035 Y Do not run engine until trouble is fixed. . OM-4435 Page 31 . voltmeter displays weld voltage and then defaults to preset voltage. 5 Engine Indicator Light Light goes on and engine stops if engine temperature exceeds 230° F (110° C) or engine oil pressure is below 10 psi (69 kPa).

Turn control from A to D to increase arc drive (dig) from min to max. Use switch to select weld process and weld output on/off control (see table below). Air Carbon Arc (CAC-A) Cutting And Gouging TIG Lift-Arc (GTAW) Output On/Off Control At Remote 14 Receptacle Engine Auto Idle (Optional) Active At Remote 14 Receptacle Active At Remote 14 Receptacle Active Electrode Hot Active Electrode Hot Active Electrode Hot Active OM-4435 Page 32 .7-3. 226 386-B / 804 009-C Process/Contactor Switch Settings Switch Setting Remote On/Off Switch Required −TIG HF Required Or Scratch Start Remote On/Off Switch Required − Stick Remote On/Off Switch Required − CV Feeder Using Remote Weld Terminals Always On − Wire Weld Terminals Always On − Stick Weld Terminals Always On − TIG Lift-Arc Process GTAW With HF Unit. Place switch in Weld Terminals Always On positions for weld output to be on whenever the engine is running. Use the Lift-Arc TIG mode for TIG (GTAW) welding using the Lift-Arc TIG starting procedure (see Section 6-4). Place switch in Remote On/Off Switch Required positions to turn weld output on and off with a device connected to the Remote 14 receptacle. When switch is in Stick mode. Or Remote Control Stick (SMAW) With Remote On/Off MIG (GMAW) w/Constant Speed Feeder MIG (GMAW) w/Voltage Sensing Feeder Stick (SMAW). Use Stick mode for air carbon arc (CAC-A) cutting and gouging. Pulsing Device. Process/Contactor Switch On CC/CV Models 1 1 Process/Contactor Switch Y Weld output terminals are energized when Process/Contactor switch is in a Weld Terminals Always On position and the engine is running. select one of four arc drive (dig) settings to provide additional amperage during low voltage (short arc length) conditions and prevent “sticking” electrodes.

Read the safety rules at the beginning of this manual.7-4. Lift-Arc™ Start Procedure Lift-Arc t TIG With Lift-Arct TIG selected. This allows electrode to touch workpiece without overheating. start arc as follows: 1 Lift-Arc Start Method 1 2 2 TIG Electrode Workpiece Turn gas on. sticking. Application: Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted. Touch tungsten electrode to workpiece at weld start point. “Touch” 1−2 Seconds Do NOT Strike Like A Match! Notes Work like a Pro! Pros weld and cut safely. The solid-state output contactor does not energize until after electrode is touching workpiece. or being contaminated. OM-4435 Page 33 . Arc is formed when electrode is lifted. Hold electrode to workpiece for 1-2 seconds. and slowly lift electrode. or to replace the scratch method. Normal open-circuit voltage is not present before tungsten electrode touches workpiece. only a low sensing voltage is present between electrode and workpiece.

Remote Voltage/Amperage Control 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-9). the Auto Sense Remote feature automatically switches voltage/amperage control to the remote control.226 386-B / 804 009-C OM-4435 Page 34 . . remote voltage/amperage control is always available regardless of the position of the Process/Contactor switch.7-5. Weld meters show preset output when not welding. In Example: Min = 20 A DC Max = 205 A DC Connect Remote Control To Remote Receptacle RC14 Set TIG or STICK Process Adjust Optional Remote Control to 100% Set V/A Control To Desired Maximum Weld Output Using Weld Meters Max (205 A DC) Min (20 A DC) Adjust Optional Remote Control to desired weld output Weld meters will always show the combined main and remote control setting and machine welds at nominal output setting of the meter. When a remote control is connected to the 1 Remote receptacle. When a device is connected to the Remote receptacle. Connect Remote Control To Remote Receptacle RC14 Set WIRE Process Adjust Optional Remote Control to desired weld output 0774 / Ref.

run engine at weld/power speed and press test button to verify ELCB1 and ELCB2 are working. Generator power decreases as weld 8-2. At least once a month. If a supplementary protector or circuit . GFCI Reset button pops out and receptacle does not work. . At least once a month. Combined output of all receptacles is limited to the 10 kVA/kw rating of the generator. If a circuit breaker continues to open. CC/CV Model Auxiliary Power Receptacles 1 2 3 4 226 386 1 2 3 110 V 16 A AC Receptacle RC12 Earth Leakage Circuit Breaker ELCB1 Earth Leakage Circuit Breaker ELCB2 tacle does not work. the receptacle does not work. RC11. If a ground fault is detected. CC Model Auxiliary Power Receptacles 1 2 3 4 5 6 Ref. the recep- . Press button to reset GFCI receptacle. Place switch in On position to reset circuit breaker. 217 359-A 1 2 220V 16 A AC Receptalce RC12 110V 20 A AC Receptacle GFCI1 4 5 Earth Leakage Circuit Breaker ELCB1 Earth Leakage Circuit Breaker ELCB2 Maximum combined output of all receptacles is 10 kVa/kW. ELCB1 protects RC12 and ELCB2 protects RC11 from overload and earth leakage fault. . 6 220V 32A AC Receptacle RC11 Receptacles GFCI1. and GFCI are working properly. If a circuit breaker opens. OM-4435 Page 35 ELCB1 protects RC12 and ELCB2 protects RC11 from overload and earth leakage fault. If a circuit breaker opens. Press button to reset. Generator power decreases as weld output increases. . breaker continues to open. 3 Supplementary Protector CB5 CB5 protects GFCI1 from overload. contact Factory Authorized Service Agent. contact Factory Authorized Service Agent. Place switch in On position to reset circuit breaker. run engine at weld/power speed and press test button to verify ELCB1. If a supplementary protector opens. .SECTION 8 − OPERATING AUXILIARY EQUIPMENT 8-1. Check for faulty equipment plugged in receptacle. the receptacle does not work. output increases. ELCB2. RC11 and RC12 supply 60 Hz single-phase power at weld/power speed. and RC12 supply 60 Hz single-phase power at weld/ power speed. 4 110 V 32 A AC Receptacle RC11 .

SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Maintenance Label OM-4435 Page 36 .

(13 mm) n Air Cleaner Element Engine Manual. Fuel Spills l = Replace Reference Section 5-6. 9-10 l Unreadable Labels Every 500 Hours nl Weld Cables Every 1000 Hours n Fan Belt Tension Z Oil Z Oil Filter n~Spark Arrestor Z FuelFilter OR Z Inline Fuel Filter nRadiator Thermostat FUEL Section 5-6. See Engine Manual and Maintenance Label Recycle engine for important start-up. n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Every 8 Hours n Coolant Level Every 50 Hours ~ Weld Terminals Every 100 Hours Section 9-5 n Fuel Level n Oil Level ~ Oil. 9-10 ~ Battery Terminals Every 250 Hours n Air Cleaner Hoses 1/2 in. Section 9-6. service. Routine Maintenance Y Stop engine before maintaining. 9-7. 9-10. 9-4. information. .9-2. and Engine Manual SLUDGE nRadiator Fluid Level ~ Inside Unit nValve Clearance* ~ Drain Sludge n~ Slip Rings* nl Brushes* Every 2000 Hours ~ Injectors* OM-4435 Page 37 . and storage fluids. Service engine more often if used in severe conditions.

If you have a problem that has not been handled to your complete satisfaction. Replace brushes if damaged or if brush material is at or near minimum length. Website Address www. IL 61552-0600 Please follow the above steps in sequence if a problem arises. Engine Division Mossville Bldg A P. Box 600 Peoria. call a Field Service Coordinator at 1-800-447-4986. 1 Generator Brush With Spring Mark and disconnect leads at brush holder cap. Your satisfaction is a primary concern to Caterpillar and to Caterpillar dealers. Customer Service.com Altitude Contact the Caterpillar applications department for information on the effect of ambient conditions on Caterpillar 3024 engines.3 mm) New Length Replace Damaged Brushes 1 Ref 226 386-B / S−0233−A OM-4435 Page 38 . follow these steps: 1 Discuss your problem with a manager from the dealership. 3 9-4. submit the matter in writing to: Caterpillar Inc. Checking Generator Brushes Y Stop engine and let cool. 2 If your problem cannot be resolved at the dealer level without additional assistance. (8 mm) Minimum Length 9/16 in. If your needs still have not been met.O.caterpillar. Manager. (14. Caterpillar Customer Assistance Service When a problem arises concerning the operation or service of the engine. 5/16 in. Remove brushes.9-3. the problem will normally be managed by the dealer in your area.

226 386-B OM-4435 Page 39 . If you decide to clean the primary element. Remove element(s). we strongly recommend installing an optional safety element to provide additional engine protection. Remove cap and dump out dust.9-5. Replace primary element yearly or after six cleanings. Servicing Air Cleaner Y Stop engine. S-0698-B / Ref. Never clean a safety element. Air pressure must not exceed 100 psi (690 kPa). 1 2 3 4 5 Housing Safety Element (Optional) Primary Element Dust Cap Dust Ejector To clean air filter: Wipe off cap and housing. Replace the safety element after servicing the primary element three times. Blow Inspect aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. Keep nozzle 2 in (51 mm) from element. Engine damage caused by using a damaged element is not covered by the warranty. The chance of dirt reaching the clean side of the filter while cleaning and the possibility of filter damage makes cleaning a risk. Replace primary element if it has holes or damaged gaskets. Wipe dust from inside cap and housing with damp cloth. Y Do not clean housing with air hose. Reinstall primary element and cap (dust ejector down). Consider the risk of unwarrantable equipment damage when determining whether to clean or replace the primary element. Replace primary element if damaged. Use 1/8 in (3 mm) nozzle and keep nozzle at least 2 in (51 mm) from inside of element. 1 2 3 4 Y Do not run engine without air cleaner or with dirty element. . Reinstall cap. Reinstall safety element (if present). Clean primary element with compressed air only. Clean or replace primary element if dirty (see note above before cleaning). The air cleaner primary element can Optional 5 be cleaned but the dirt holding capacity of the filter is reduced with each cleaning.

Run engine until engine reaches normal operating temperature. Check coolant level in recovery tank. 3 Exhaust Pipe Start engine and run at idle speed to blow out cleanout hole.9-6. briefly cover end of exhaust pipe with fireproof material. Add coolant if necessary. 226 386-B 9-7. Servicing Engine Cooling System Y Stop engine and let cool. Add coolant according to Section 5-6). Reinstall cleanout plug. 2 After engine cools. 1 2 Radiator Draincock Radiator Cap Cover Change coolant according to engine manual. 1 804 009−C / Ref 226 386-B OM-4435 Page 40 . Y Stop engine and let cool. 1 3 2 Tools Needed: 3/8 in 803 582-F / Ref. Inspecting And Cleaning Spark Arrestor Muffler Y Stop engine and let cool. If nothing blows out of hole. 1 2 Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. check coolant level again and add coolant if necessary.

Engine speed is factory set and should not require adjustment. Close door. Tampering with adjustments other than shown may affect engine warranty. 3 Engine Stop Lever Y Stop engine.9-8. Turn Process/Contactor switch to Weld Terminals Always On − Stick position. See table for proper no load speed. After tuning engine. If necessary. Adjusting Engine Speed On Standard Models Y Stop engine and let cool.7) Maximum 3 . Turn screw until engine runs at weld/power speed. 1 Lock Nut 2 Adjustment Screw Loosen nut. Engine Speed (No Load) Weld/Power RPM (Hz) 1850 (61. adjust speed as follows: Start engine and run until warm. check engine speed with tachometer or frequency meter. Do not set engine speed higher than specified. 2 1 Tools Needed: 804 009−C OM-4435 Page 41 . Tighten nut.

Y Stop engine. Turn Process/Contactor switch to Stick − Weld Terminals Always On position. Loosen lock nut. Turn throttle rod and plunger until engine runs at idle speed.9-9. . Unhook rubber boot from the solenoid housing but leave connected to plunger.6 Hz) 1500 rpm (50 Hz) After tuning engine. Place Engine Control Switch in Auto position. check engine speed with tachometer or frequency meter. Hook rubber boot back onto solenoid housing. Weld/Power Speed Adjustment . Weld/power speed 1 adjustment must be done by the engine manufacturer’s factory authorized service agent. However. To 2 3 prevent solenoid damage. be sure a 1/8 in (3 mm) gap exists between the engine low speed screw and throttle lever when the solenoid is held in the energized position. If necessary. Tighten lock nut. See table for proper no load speed. adjust speed as follows: Start engine and run until warm. 4 . 1 2 3 4 Throttle Rod / Plunger Lock Nut Rubber Boot Adjustment Screw Adjustment screw is not used to adjust engine speed when automatic idle option is installed. it must be at least 1/8 in (3 mm) away from the throttle arm when engine is running at idle rpm. 803 563-G OM-4435 Page 42 . Tampering with adjustments other than shown may affect engine warranty. Adjusting Engine Speed On Models With Automatic Idle (Optional) Engine Speed Adjustment Engine Speed (No Load) 1880 rpm max (62. Be sure solenoid plunger pulls all the way in (“bottoms”) when energized.

Apply thin coat of fuel to gasket on new filter. Close door. Use adequate blocks or stands to support unit while draining fuel tank. See engine manual and engine maintenance label for oil/filter change information. Y After servicing. and replace if cracked or worn. reconnect fuel lines. Servicing Fuel And Lubrication Systems Y Stop engine and let cool. and use screwdriver to open sludge drain valve. start engine and check for fuel leaks. Fill new filter with fresh fuel. To drain sludge from fuel tank: Y Beware of fire. Remove fuel line clamps and disconnect fuel lines from fuel filter. Replace filter. tighten connections as necessary. Close valve when sludge has drained. and reinstall clamps. 2 6 To drain water from fuel system: See engine manual. Dispose of drained fuel in an environmentally-safe manner. To replace primary (canister) fuel filter: Turn filter counterclockwise. Install new filter and turn clockwise.9-10. Attach 1/2 ID hose to drain valve. Inspect fuel lines. 5 Y Properly lift unit and secure in a level position. Tools Needed: 4 3 1 Ref 226 386-B / 804 009−C OM-4435 Page 43 . and wipe up spilled fuel. Remove filter. 1 2 3 4 5 6 Oil Filter Oil Drain Valve And Hose Oil Fill Cap Primary (Canister) Fuel Filter Secondary (In-Line) Fuel Filter Fuel Tank Sludge Drain Valve To change oil and filter: Route oil drain hose and valve through hole in base. Put metal container under drain. To replace secondary (in-line) fuel filter: Note direction of fuel flow as indicated by arrow on side of filter. Do not leave unit unattended while draining fuel tank. Stop engine. Remove hose. Do not smoke and keep sparks and flames away from drained fuel.

If CB3 opens. If CB8 opens. If CB2 opens. or fuse opens. CB1 automatically resets when the fault is corrected. weld and generator power output stops. CB3 protects part of the weld control wiring harness. weld and generator power is low or stops entirely. it usually indicates a more serious problem exists. 6 4 Circuit Breaker CB9 CB9 protects the throttle solenoid against overload. When a circuit breaker. 226 386-B / 803 566-E / 804 009-C OM-4435 Page 44 . 24 volt output to RC14 stops. the engine does not automatically idle down. Overload Protection Y Stop engine. If CB9 opens. Check the linkage and solenoid. Contact Factory Authorized Service Agent. If CB1 opens. the engine will not crank. the engine will not crank. 2 3 4 5 Circuit Breaker CB1 (Not Shown) Supplementary Protector CB2 Supplementary Protector CB3 Supplementary Protector CB8 CB1 protects the engine battery circuit. 1 Fuse F1 F1 protects the stator exciter winding from overload. CB2 protects the engine wiring harness.9-11. supplementary protector. 3 CB8 protects the 24 volt ac output to remote receptacle RC14. 1 6 5 Ref. If F1 opens. Press button to reset supplementary protector. CB9 automatically resets. .

and main control module PC1. filter board PC6. 1 HL. and the wiring between PC1 and PC2. 4 Help 23 Display Indicates one of the rectifier output SCR’s has failed. have Factory Authorized Service Agent check PC1. and the wiring between TH1 and PC1.P 3 reset help displays. Keep engine access door closed when running to maintain proper cooling air flow past rectifier. 2 Help 21 Display Indicates thermistor TH1 on the main rectifier heat sink has failed. 3 Help 22 Display Indicates the rectifier heat sink has overheated. have Factory Authorized Service Agent check the remote device. Help 25 is also displayed whenever a remote device has been connected to RC14 and then disconnected. If problem continues. Allow unit to cool before restarting. PC2. or the wiring between PC2 and main control module PC1. If this display is shown. 5 Help 24 Display Indicates weld open circuit voltage (OCV) is too high (above 41 volts dc). If this display is shown. stop unit and then restart.P 6 HL. Clear fault by stopping and restarting the unit or by turning Process/Contactor switch to another position. have Factory Authorized Service Agent check unit. . Optional Voltmeter/Ammeter Help Displays Use the Voltmeter/Ammeter help displays to diagnose and correct fault conditions. See item 6 below to reset Help 25 display. have Factory Authorized Service Agent check the rectifier SCR’s. 1 Help 20 Display HL.9-12. If problem continues.P 4 Indicates a failure of meter display module PC2. have Factory Authorized Service Agent check TH1. 6 Help 25 Display Indicates a remote device connected to Remote Receptacle RC14 may be faulty.P 5 HL. 804 009-C OM-4435 Page 45 .P Ref. When a help code is displayed normally weld output has stopped but generator power output may be okay. To HL. have Factory Authorized Service Agent check main control module PC1. If this display is shown. check generator cooling system and/or reduce duty cycle. If this display is shown.P 2 20 21 22 23 24 25 . If this display is shown. HL.

313 in) 3/8 in (.25 in) 5/16 in (.025 in) 22 Gauge (.188 in) 1/4 in (.031 in) 20 Gauge (.125 in) 3/16 in (.5 in) OM-4435 Page 46 .Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.037 in) 18 Gauge (.375 in) 1/2 in (.078 in) 1/8 in (.

No 24 volt ac output at Remote recep. Check for faulty remote device connected to RC14. Remedy No weld output. tacles.Reset receptacle supplementary protectors (see Section 8-1). If F1 is open. generator power output Place Process/Contactor switch in a Weld Terminals Always On position. No remote fine amperage control. and field excitation circuit. Reset supplementary protector CB8 (see Section 9-11). voltage regulator module PC3. Have Factory Authorized Service Agent check brushes and slip rings. and replace if open (see Section 9-11). Be sure connection to work piece is clean and tight. Check fuse F1. and replace if open (see Section 9-11). Repair or replace remote control device. Check Voltmeter/Ammeter help displays (see Section 9-12). Check Voltmeter/Ammeter help displays (see Section 9-12). have Factory Authorized Service Agent check the rotor. Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 5-9). (see Section 9-11). Use dry. Have Factory Authorized Service Agent check main control module PC1. Low open-circuit voltage. Check and tighten connections inside and outside unit. have Factory Authorized Service Agent check the voltage regulator module PC3. put at ac receptacles. No weld output. On/Off Switch Required position and turn remote contactor on (see Section 6-3). voltage regulator module PC3. OM-4435 Page 47 .9-13. Check fuse F1.Disconnect equipment from generator power receptacles during start-up. or generator power out. Have Factory Authorized Service Agent check brushes and slip rings. Remove excessive coils from weld cables. Check engine speed. Reset supplementary protector CB3. and main rectifier. tacle RC14. weld output okay. Disconnect equipment from generator power receptacles during start-up. Low weld output. Check and secure connections to Remote Control receptacle RC14 (see Section 5-9). Troubleshooting Note A. Erratic weld output. properly stored electrodes. Check engine speed. Standard Generator Power Trouble Remedy No generator power output at ac recep. and adjust if necessary.Reset supplementary protector CB8 (24 volt) (see Section 9-11). High weld output. Welding Trouble Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 9-12). or place switch in a Remote okay at ac receptacles. No generator power or weld output. B. Have Factory Authorized Service Agent check main control module PC1 and hall device HD1. and adjust if necessary. If F1 is open.

Keep battery in good condition. Check fuel level. and field excitation circuit. Automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high (see Section 5-6 ).Check engine speed. have Factory Authorized Service Agent check the rotor. and control relay CR2. Have Factory Authorized Service Agent check Engine Control switch S1. CB1 automatically resets when fault is corrected (see Section 9-11). Check battery. engine harness. integrated rectifier SR2. See engine manual. control relay CR3. Remedy OM-4435 Page 48 . Check oil and coolant levels. High output at generator power ac re. and the fuel pump. Check Voltmeter/Ammeter help displays (see Section 9-12). Store battery in warm area off cold surface. Have Factory Authorized Service Agent check voltage regulator module PC3. Engine slowly stopped and cannot be restarted. Have Factory Authorized Service Agent check engine wiring harness and components. and replace if open (see Section 9-11). Check engine charging system according to engine manual. tacles. Circuit breaker CB1 may be open. and the fuel pump. Reset supplementary protector CB2 and/or clear fault causing circuit breaker CB1 to trip (see Section 9-11). Check fuel level. ceptacles. Have Factory Authorized Service Agent check brushes and slip rings. Have Factory Authorized Service Agent check control relay CR1. Engine cranks but does not start. and the fuel pump. fuel solenoid FS1. Reset supplementary protector CB3 (see Section 9-11). Engine hard to start in cold weather. C. Check battery and replace if necessary.Trouble Remedy Check fuse F1. Contact local fuel supplier for fuel information. Use correct grade oil for cold weather (see Section 9-1). Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Use Preheat switch S4 (see Section 6-2). Check engine air and fuel filters (see Sections 9-5 and 9-10). control relay CR1. Check engine wiring harness plug connections. Reset supplementary protector CB2 (see Section 9-11). Have Factory Authorized Service Agent check engine alternator. Engine Trouble Engine will not crank. fuel solenoid FS1. and replace if necessary. fuel solenoid FS1. and adjust if necessary. and the glow plug. Low output at generator power ac recep. Air in fuel system. and replace if open (see Section 9-11). Have Factory Authorized Service Agent check Engine Control switch S1. Check battery connections and tighten if necessary. If F1 is open. Engine suddenly stops. Check fuse F1. Have Factory Authorized Service Agent check Preheat switch S4. See engine manual. See engine manual.Have Factory Authorized Service Agent check voltage regulator module PC3.

Periodically recharge battery (approximately every 3 months). Engine uses oil during run-in period. Check for obstructed throttle solenoid. Dry engine according to run-in procedure (see Section 11). Engine does not run at idle speed (units with idle option only). Clean top of battery with baking soda and water solution.Trouble Battery discharges between uses. CB9 automatically resets when fault is corrected (see Section 9-11). Recharge or replace battery if necessary. and control relay CR4. Engine idles. but does not come up to weld speed (units with idle option only). Remedy Turn Engine Control switch off when unit is not running. Circuit breaker CB9 may be open. Have Factory Authorized Service Agent check idle module PC5 and current transformer CT1. Check for obstructed throttle solenoid. OM-4435 Page 49 . Have Factory Authorized Service Agent check idle module PC5. wetstacking occurs. rinse with clear water.

Circuit Diagram For CC Welding Generator OM-4435 Page 50 .SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1.

226 564-C OM-4435 Page 51 .

Figure 10-2. Circuit Diagram For CC/CV Welding Generator OM-4435 Page 52 .

226 566-D OM-4435 Page 53 .

Piston rings seat faster if engine runs at weld/ power rpm. black. dry the engine using one of the following run-in procedures. If exhaust pipe is coated with a wet. rating label. or specifications section in this manual to find rated voltage and current. tar-like substance. and the welding generator is kept loaded during run-in. OM-4435 Page 54 .SECTION 11 − RUN-IN PROCEDURE run_in1 11/05 11-1. 1 2 Welding Generator Run diesel engines near rated voltage and current during run-in period to properly seat piston rings and prevent wetstacking. 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. See the engine manual for additional engine run-in information. . See nameplate. 1 2 Do not idle engine longer than necessary. Wetstacking Y Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur.

3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct connectors. Observe correct polarity. Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly. 4 Engine Exhaust Pipe Repeat procedure if wetstacking is present. Set load bank switches and then adjust generator A/V control so load equals rated voltage and current of generator (see nameplate. connect load bank to 115 volts ac wall receptacle or generator auxiliary power receptacle. S-0683 OM-4435 Page 55 . Y Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. It is recommended to run the welding generator for two hours minimum and up to four hours under load. 2 Welding Generator Place A/V range switch in maximum position. A/V control in minimum position. Y Do not touch hot exhaust pipe. or the specifications section in this manual). or load bank/grid. Y Stop engine and let cool. Place A/V control in minimum position.11-2. engine parts. Check oil level frequently during run-in. 3 . If needed. 1 Load Bank Turn all load bank switches Off. Start engine and run for several minutes. add oil if needed. rating label. Run-In Procedure Using Load Bank Y Stop engine. then turn off load bank to remove load. Run engine several minutes at no load. 4 2 1 Y Keep exhaust and pipe away from flammables. and Output Selector switch (if present) in either DC position.

2 Welding Generator Place A/V range switch in maximum position. engine parts. 6 2 Y Keep exhaust and pipe away from flammables. add oil if needed. Set grid switches and then adjust generator A/V control so load equals rated voltage and current of the generator (see nameplate. 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present. Y Do not touch hot exhaust pipe. Run-In Procedure Using Resistance Grid Y Stop engine. S-0684 OM-4435 Page 56 . or the specifications section in this manual). 3 Weld Cables Connect grid to generator weld output terminals using proper size weld cables with correct connectors (polarity is not important). 1 Turn Off grid. and Output Selector switch (if present) in either DC position. then shut down grid to remove load. . A/V control in minimum position. It is recommended to run the welding generator for two hours minimum and up to four hours under load.11-3. Start engine and run for several minutes. 1 Resistance Grid Use grid sized for generator rated output. Y Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. Y Stop engine and let cool. Check oil level frequently during run-in. if not provided on generator. 3 5 4 + Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly. 4 Voltmeter 5 Clamp-On Ammeter Connect voltmeter and ammeter as shown. or load bank/grid. Place A/V control in minimum position. Run engine several minutes at no load. rating label.

and some running gear insulate the welding generator from the vehicle frame.SECTION 12 − GENERATOR POWER GUIDELINES NOTE The views in this section are intended to be representative of all engine-driven welding generators. gen_pwr 11/02 − Ref. use GFCI-protected extension cord. 12-1. Electrically bond generator frame to vehicle frame by metal-to-metal contact. 1 2 3 OR Be sure equipment has this symbol and/or wording. ST-159 730 / ST-800 577 12-2. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown. Use #10 AWG or larger insulated copper wire. Your unit may differ from those shown. S-0854 OM-4435 Page 57 . Grounding Generator To Truck Or Trailer Frame Y Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. Selecting Equipment 1 2 3 Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Y Do not use 2-prong plug unless equipment is double insulated. shipping skids. 1 2 1 GND/PE 3 2 Equipment Grounding Terminal (On Front Panel) Grounding Cable (Not Supplied) Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame. Y Bed liners. 3 Y If unit does not have GFCI receptacles.

4. How Much Power Does Equipment Require? 1 3 2 1 VOLTS 115 AMPS 4. (200 W + 200 W + 200 W) + 520 W = 1120 W The total load applied by the three flood lamps and drill is 1120 watts.5 Hz 60 Resistive Load A light bulb is a resistive load and requires a constant amount of power. 3 Ground Device Y Ground generator to system earth ground if supplying power to a premises (home.12-3. 2 Non-Resistive Load Equipment with a motor is a non-resistive load and requires approximately six times more power while starting the motor than when running (see Section 12-8). S-0623 OM-4435 Page 58 . shop. ST-800 576-B 12-4.5 amperes at 115 volts. 3 3 Rating Data Rating shows volts and amperes. 2 3 Use ground device as stated in electrical codes. farm) wiring system. calculate its running power requirement in watts. add the individual loads to calculate total load. or watts required to run equipment.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. Grounding When Supplying Building Systems 1 1 GND/PE 2 2 Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.

g. Air Compressors) Rating 1/4 HP 1/2 HP 3/4 HP 2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/2 HP 500 PSI 550 PSI 700 PSI 1/3 HP 1/2 HP 1/3 HP 1/2 HP Starting Watts 1000 1650 3400 4400 2900 10500 1720 2575 4500 6100 8200 10550 15900 23300 8100 23300 35000 46700 3300 3150 4500 6100 3100 2150 3100 2100 3200 Running Watts 1000 650 1000 1400 1100 2800 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 1000 950 1400 1600 800 750 1000 800 1050 High Torque (e. Barn Cleaners.8 Gal/Min Washer 2 gal/min 2 gal/min Refrigerator or Freezer Shallow Well Pump Sump Pump OM-4435 Page 59 . Bunk Feeders) 3-1/2 cu.12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Rating 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP Starting Watts 800 1225 1600 2100 3175 2020 3075 4500 6100 8200 10550 15900 23300 8100 23300 35000 46700 1000 1400 1850 2400 3500 Running Watts 300 500 600 700 875 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 400 550 650 800 1100 Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 12-6. Conveyors. Silo Hoists. ft. Silo Unloaders. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std. Feed Augers.g. Mixer High Pressure 1. (e.

12-7. 12 in 2 HP. 14 in Standard 9 in Heavy Duty 12 in 1/3 HP 18 in HID Metal Halide Mercury Sodium Vapor 400 gph 900 gph 3/4 HP. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet & Dry Vac 1000 200 500 1400 1600 950 1400 1600 700 900 1300 OM-4435 Page 60 .7 HP 2-1/2 HP Starting Watts 350 400 600 500 900 1400 4500 6300 2500 1720 3900 5200 3000 6000 8200 10500 1100 1100 350 500 2100 400 125 313 1000 1400 1250 600 900 4500 6100 3150 4500 6100 1900 900 1300 Running Watts 350 400 600 500 900 1400 1500 1800 1100 720 1400 1600 1000 1500 2200 2800 1100 1100 350 500 700 400 100 250 Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. 20 in 1/2 HP 3/4 HP 1 HP 1/4 HP 1. 16 in 1 HP. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Rating 1/4 in 3/8 in 1/2 in 6-1/2 in 7-1/4 in 8-1/4 in 9 in 10 in 14 in 6 in 8 in 10 in 1/2 HP 1 HP 1-1/2 HP 2 HP 1-1/2 HP.

5 P 14.1 J 8.2 kVA/HP x HP x 1000 VOLTS = STARTING AMPERAGE EXAMPLE: Calculate the starting amperage required for a 230 V.0 M 11. N 12. Code M results in kVA/HP = 11. How Much Power Can Generator Supply? 1 Limit Load To 90% Of Generator Output Always start non-resistive (motor) loads in order from largest to smallest. and add resistive loads last. Power Required To Start Motor 4 1 3 AC MOTOR VOLTS 230 AMPS 2.2 11.0 L 10.5 CODE M Hz 60 HP 1/4 PHASE 1 2 1 2 3 4 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.0 K 9. Motor requires more power than generator can supply.2 x 1/4 x 1000 = 12.0 Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP G 6.3 H 7. If code is not listed. 230 S-0624 12-9. Step 2: Find Motor HP and Volts.12-8. 2 Ref. ST-800 396-A / S-0625 OM-4435 Page 61 . turn off power to prevent motor damage. Volts = 230 HP = 1/4 Using Table. Step 3: Determine starting amperage (see example). Welding generator amperage output must be at least twice the motor’s running amperage.2 A Starting the motor requires 12.2 amperes. 1 2 5 Second Rule If motor does not start within 5 seconds. 1/4 HP motor with a motor start code of M. multiply running amperage by six to find starting amperage.

Y Properly install and ground this equipment according to its Owner’s Manual and national. 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular (utility) system voltage and wiring. heaters. and local codes. OM-4435 Page 62 . 3 Fused Disconnect Switch Install correct switch (customer-supplied) if required by electrical code.12-10. Read the safety rules at the beginning of this manual. state. Connect generator with temporary or permanent wiring suitable for the installation. etc. Transfer load back to electric utility when service is restored. 1 Utility Electrical Service 2 Transfer Switch 3 Fused Disconnect Switch (If Required) 4 Welding Generator Output 5 Essential Loads Y Have only qualified persons perform these connections according to all applicable codes and safety practices. freezers. Install correct switch (customer-supplied). Typical Connections To Supply Standby Power Y Properly install and ground this equipment according to its Owner’s Manual and national. Switch rating must be same as or greater than the branch overcurrent protection. and local codes. . If generator does not produce enough output to meet all requirements. connect only essential loads (pumps. the engine has low speed which causes low voltage and frequency. Turn off or unplug all equipment connected to generator before starting or stopping engine. state. Customer-supplied equipment is required if generator will supply standby power during emergencies or power outages. 5 Essential Loads Generator output may not meet the electrical requirements of the premises. − See Section 12-4). Switch transfers the electrical load from electric utility service to the generator. 1 Utility Electrical Service 2 Transfer Switch (Double-Throw) Notes Work like a Pro! Pros weld and cut safely. When starting or stopping.

000 800 (244) 600 (183) 450 (137) 350 (107) 300 (91) 250 (76) 225 (69) 200 (61) 175 (53) 800 (244) 550 (168) 350 (107) 275 (84) 225 (69) 175 (53) 150 (46) 125 (38) 125 (38) 100 (31) 4 6 8 700 (213) 500 (152) 350 (107) 225 (69) 175 (53) 125 (38) 100 (31) 100 (31) 75 (23) 10 450 (137) 300 (91) 225 (69) 150 (46) 100 (31) 75 (23) 75 (23) 12 225 (84) 200 (61) 125 (38) 75 (23) 60 (18) 14 200 (61) 125 (38) 100 (31) 60 (18) *Conductor size is based on maximum 2% voltage drop OM-4435 Page 63 . Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) 5 7 10 15 20 25 30 35 40 45 50 Load (Watts) 1200 1680 2400 3600 4800 6000 7000 8400 9600 10.800 12. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) 5 7 10 15 20 25 30 35 40 45 50 Load (Watts) 600 840 1200 1800 2400 3000 3600 4200 4800 5400 6000 400 (122) 300 (91) 225 (68) 175 (53) 150 (46) 125 (38) 112 (34) 100 (30) 87 (26) 400 (122) 275 (84) 175 (53) 137 (42) 112 (34) 87 (26) 75 (23) 62 (19) 62 (19) 50 (15) 4 6 8 350 (106) 250 (76) 175 (53) 112 (34) 87 (26) 62 (19) 50 (15) 50 (15) 37 (11) 10 225 (68) 150 (46) 112 (34) 75 (23) 50 (15) 37 (11) 37 (11) 12 137 (42) 100 (30) 62 (19) 37 (11) 30 (9) 14 100 (30) 62 (19) 50 (15) 30 (9) *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles. use GFCI-protected extension cord.12-11. use GFCI-protected extension cord. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles.

8 9 10 11 12 14 15 16 103 17 102 19 4−Fig.13-3 98 97−Fig. Hardware is common and not available unless listed.SECTION 13 − PARTS LIST . Main Assembly OM-4435 Page 64 .13-5 3 100 1 2−Fig.13-2 99 85 88 93 94 95 96 86 87 80 83 82 81 101 18 90 89 91 20 22 21 24 25 13 6 7 5 23 106 105 104 92 84 Figure 13-1. Wiring harnesses are listed at the end of parts section.

803 683-D OM-4435 Page 65 .13-4 76 73 68 66 67 65 61 64 63 62 60 59 58 57 56 55 46 47 49 36 45 50 48 51 43 44 52 46 53 54 75 74 55 Optional Auto Idle 109 108 107 804 012−A / Ref.28 27 29 30 31 32 40 35 41 42 26 33 34 38 37 39 69 70 71 78 79 77 72−Fig.

. . . . . . . . . . . .500 In W/Vent W/Lanyard 8” . . . . 38 . . 36 . 212621 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket. . . . . . . . . . . . . 14 . Fuel Pump/Filter . . . . . . . . . . . . . . . . 213929 . . . . . . . . . . . . 37 . . . . . . . . . . . . 190190 . .. . Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Nut. . . 190198 . . . . . . . . . 088528 . . . Rectifier . 220295 . . . . . . . . . . Fuel Spin−on . . . Bracket. 8 . . . . . . . . .. Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upright. . . . . . . . . . . . . . . . . . . . . . Radiator Access . . . . . . . Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214604 . . . . . . . . (Order Thru Engine Manufacturer) . .. . . . . . Cover. . . . . . . . PC1 . . . . . . . . . . . . . . 18 . . . . . 45 . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . 189052 . . +213487 . . 225120 . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . . . . . . . 192303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 . . . . . . . . . . . . . . . . Exhaust Flexible Inlet . . . . . Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217698 . .. . . . . 25 . . . . . . . . . . . Label. . . . . . . . . . . . . . . . . Bracket. . . . . Air Upper Radiator . . . . 11 . . . . Pipe. . . . . . . . . 42 . . . . . . . . . . . . . . 215268 . . . . . . . . . . . . .. . . . . Dia. . Grommet. . . . . . . . . . . . . . . . . . . . . +213488 . . . . . . . . . . . . . . . . . . . . Bracket. Label.. . . . . . . . . . . . . . . . . . . . 212603 . . . . . . . . . . . . . . . . . PC3 . . Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . Coolant Recovery . . . . Vault . . . . . . . . . . . 189464 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . .. . . . . . . . . . . . . . . . . Label. . . .250 Inlet/Outlet (Includes) .. . . . . . . . Radiator. . . . . . . . . . . . . Engine Side . 201399 . . . . . . . . . . . . . *213858 . . . . . . . . . . . . . . . . . . 226018 . Mtg Stabilizer . . . . . . . . . . . . . . . . . . +212607 . . . . . Bracket. . . . . . . . . . . . . . . . . . . . . 213503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . . Muffler 1. . . . . . . . 213472 . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . Latch Engine Access . . . . . . . Filter. . . . . . Keeper. . Fuel . . . . . . . . . . . . . Main Assembly Quantity . . . . . . 225412 . Door. . . . . . . . 22 . . . . . . . .. . . . . 168829 . . . . 35 . . . . . . . . . . . . . . . . . . . . . . . . . . 212604 . . . . . Gasket. . . . 20 . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . . . . Paddle Series 20 (Black) . . . . 43 . . . . . . 9 . . . . . . . . . 23 . . . . . . . . . Center Assy . . . . . . . . . . . . Plastic Neck Filler Fuel . . 49 . . . . . . . . . . . .. . . . . . . . . . . . Shroud. Module. . . . . . . . . . . . . . . . . 214770 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Hot Exhaust Parts Do Not Touch . . . . . . . . Weather Lift Eye . . . . . . . . . 187120 . . . . . . . . . . Exhaust . . . 181853 . W/14# Cap 3 Row Core 1. . . . . . . Control Panel . . . . . . . . 6 . Main Control/Scr Gating . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guard. . . 217687 . . . . . . 203260 . . . . . . . . . . . Z1 . . . . . . . . . . . . . . HD1 . . . . . . . . . . . . . . . . . . . . . . . . . . 213493 . . . 213602 . . . Baffle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . . . . . . . Mkgs. . . . . . . . . . . . . . . . . . . Panel. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 213580 . . . . . . . Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . . . . . . . . . . . 21 . . . . . OM-4435 Page 66 1 1 1 1 4 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 1 1 1 1 1 1 8 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 3 . . . . . . . . . . . . . . . . . . . . . . . . . . Baffle. . 222513 . . .. . . . . . Upright. . . . . . . Latch. . . . . . . . . . . . . . . .. Screw (For Rectifier Mtg) . . . . . . . . . . . . . . . . . 183314 . . . . . . . . . . . . . . . .. 191626 . . . . . . . . . . . . . 26 . . +213470 . . 199592 . . 231705 . . . . . Module. . . . . . . . . . . . . . . . . Description Figure 13-1. . Bracket. . 213501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . +225400 . Muffler. . . . . Baffle. 192041 . . . . . . . . . . . . Label. . . . . . . . . . . . . . Top . . . . . . . . . . . Door Engine Access . . . . . Guard. . . . . . . . . Cap. . . . . . . . . . . . . . . . . 224265 . . . . . . . . . . . . . . . . . . . Bumper. Caution Do Not Use Ether . . .. . . . . . . . . . Holddown Fuel Tank . . . . . . . . . . Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transducer. . . . . . . . . . . . . . . . . . . . . . 47 . . . . . . . . . . . . Fan . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover Top . . . . . . . . . . . . . . . . . Warning Moving Parts Can Cause Injury . . . Part No. . . . . . . . . . . . . Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 . . . . . . . . . . . . . 33 . . . . . . . . . . . 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176108 . . . . . . Fan . . . . . . . . . . . . Figure 13-7 Rectifier Assembly . . . . . . . . . . . 049525 . . . . . . . . . Fuel Filter Mtg. . . . . . . . Figure 13-4 . . . . . . Pipe. . . . . . . . . . 5 . . . . . . . . . . . . . . 19 . . . .. . . . 27 . . . . . . . . . . . . . . . . 233256 . . . . . . Radiator Access . . Rear . 16 . 217387 . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . . . . . . . . . . . . . .0” Long . . 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . .Item No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 46 .. . . . . Label. . . . . . . .. . . . . . 30 . . . 213471 . .. . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer . . . . . . . . . . . . . . . . . . . . Engine Access . . .. . . . . . . . . . . . . . . . . . . . . . . . . . Diesel Engine Maintenance Cat 3013c . . Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . Radiator . . . . . . 214753 . .. . . . . . . . . . . Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insulator. . . . . Fan . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . .. .. . . . . . . . . Cap. . . . . . . . . . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . . . . . . Voltage Regulator . . . . . . . . . . 213502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . . . . . . .. Spark Arretsor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Engine . . . . . . . . . .. . . . . . . . . . . . Angle. . . . Air Lower Radiator . . . . . . . . . . . . . 217070 . Bracket. . . . . . . 44 . . . . . . . . . . . . 215522 . . . . . Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201851 . Pipe. . . . . . . . Radiator Pressure 14lb . . . . . . . . . . . .. . . . . . . 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . .625 Dia U Pld . . Cover. . . . . . . . . . . . . . . . Tank Screw−on 3. Use Diesel Fuel Only . . . . . . . . . . . 39 . . . . . . . . . 15 . . . . . . . . . . . . . . Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Extension 5. . 32 . . . . . . . . .. Pipe. . . . . . . . . . . . . 29 . . . . . . . . Exhaust Elbow . . . . .. . . . . . . . . . . . . . . . . . . . . Exhaust Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 . . . . . . . . . . . . . . . . Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . 207721 . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . Sae . . . . . . . . . . 61 . . . . . . . . . . . . . . . . . . . . . . .Item No. . . . . . . . . . . . . . . . 74 . . . . . . . . . . . . . . . . . . . . . . 84 . . . . . . . . . 1 . . Switch. . . . . . Base . . . . . . . 213462 . . . . . . . 212610 . . . . . . . . . . . 213466 . . . . . . . 75 . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . .187t Stl Pld . . . . . . . . . . . . Hose Brs Barbed Elbow M 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . .8 Pln . . . . . . . . . . . . . Generator . . . . . . Fuel Stand Pipe W/3/16 In Ftg (Return) . . . . . . . . . . . . . . 70 . . . . . . . . . . Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free . . . . . . . . Cable. . . . . . . . . . . . . . . 2 OM-4435 Page 67 . . . . . . . . . . . . . . . . . . . . . . 55 . . J Stl . . . . . . . . . . . . . . . .000 Od X . . . . . . . . . . . . . . . . . . . . . . . . . 213459 . . . . 1 . . . . . . . . . 53 . . 78 . 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210792 . . . . . Bushing. . . . . . Air Intake . . . . . . . . . . . . . . Spacer/Snubber. . . . . 63 . . . . 1 . . . . . . Mount. . . . . . . . . . . . . . . . . . Bracket. . . . . . . . . . . Sae . . . 189975 . Alternator . . . . Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake 5. . . . . . . . Radiator Upper . . . . . . . . . . . . . 212623 . . . . . . . . . . 8 . . . . . . . . . .605 Clp Dia Slfttng Black . . . . . . . . . . . . . . 087341 . . . . 1 . . Main Assembly (Continued) Quantity . . . . . . . . . . . 65 . . . Label. . . . . . . . . . .520 − . . . . . . . . . . . . . . . . . . . . . . . . . . . Crossmember. . . . . . . . . . . . . 197678 . . 1 . . . SENDER . . Engine. . . . . . . . . Sae . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . 2 . . . .312−18 X 7. . . . . . . . . 2. 213486 . . . . . 2 . . . . . . . . . . . . . . . . . . . . . . . . . Bushing. . . . . . . . . . 197613 . . . . . . . . . . . . . . Adapter Oil Drain Cat 3013 . . . . . . . . . . . . . . .312 Id X . 500−13x2. . . . . . . Dia. . .5x 30 Hex Hd−pln 8. . . . . . . . . Oil Drain 3/8−18 Nptf . . . . . 1 . . . . . . . . . . 197448 . . . . . . . . . . . . . . . . . . . . . . . *197676 . . . . . 73 . . . . . . . . . Tank Fuel . . 2 . . . . . . . . . . . . .000 Lg (Includes) . . . Oil Cat−150−4140 . . . . . . . . . . . . . 213458 . . . . . . . *202166 . . . . . . . . . . Ftg. . . Flat . . Hose. . . . . . . . . . .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . .087t Stl Split10mm . . . . . . . . . . . 1 . . . 1 . . Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . .25 Hex Flange−hd Gr8 Pln Chem/Phys . . . . . . . Battery Holddown . . . . . . . . . . . . . . . . Fuel Gauge . . . . . . . . . . . Panel. . 217695 . . . . . 213480 . . . . . . . . . . . . . . . . .406 Rng . . . . .560 Od (order by foot) . . . . . . . . . . . . . . . . . 4 . . . . . . . 197677 . . . . . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Access 180 Deg . . . . . . Ftg. . . 1 . . . . . . . . . . . . . . . . . . . . Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 . . . . . . . . . . . . . . . . Fuel (Includes Fuel Cap And Items Below) . . . . . Lubricating Oil Pressure N. . . . 1 . . 224266 . . . . . . . . . . 190206 . . . . . . . . . . Part No. . . . . Screw. . . . . . . . . Bracket. . . . 134835 . . . . . 216811 . . Tank Fuel . . . . . . . . . . . . . . . Hose Assy. . . . . . . . . . . . . . . . . . . . . . . Hose . . . 1 . Bracket. . . . . . . 176529 . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . 1 . . . . . . . . . . . . . . 212614 . . . 60 . . . . . . . . . . . . . . . . . . . . 79 . . . . 217696 . . . . . Hose. . . . . . . . . Bat Neg 42 In Lg 2 Awg W/Clamp & .250 In (Includes) . Air Cleaner. . . . . . . . . . . . . . 89 . . . . . 213265 . . . . . . . . . . . . 213465 . . . . . . . . . Hose. . Battery. . . . . . . . . . . . . . . . . . . Crossmember. . . . . Hose. . . . . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . 69 . 1 . . . . . . . . . . . . . . . . . . 071731 . . . . . . Mtg Air Cleaner . . . . . . . . . . 54 . . . Description Figure 13-1. . . . . . . . . . . . . . . M10−1. . . . . . . . . . Hinge. . . . . . . . . . . . . . .C. . . Pad. . . . . . . . . . . . . . . . . . . Coolant Temp N. . . . . . . . . . . . . . . . . 1 . . . 212613 . . . . . . .250 Pld . . . . . . . Bolt. . . . . . . . . .250odx. . . . . . . . . . . . . . . . . . . . . . . Engine . Warning Do Not Weld On Base . 197506 . Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . Generator Mtg . . 1 . . . . . . . . . . . . . . . . . . . . . . .187 Id X . . . . . 1 . . Valve. . . . . . . Engine/Generator Flange Mtg . . . . . . . . . 1 . . . . . . . . . . . 77 . . . 083883 . . . . . . . Hose. . . . . . . . . . . . ♦*197679 . . . . . . . . . . . . . . . . . Hose. . . . . . Figure 13-5 . . . . . . . . . . . . .410 Od X 26. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bumper. . . . . 165271 . . . . Screw. . . . . . 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner . . . . . . . . . . . . . . . . . . 113854 . . . . . . . . . M14−1. . . . 199505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 . . . 88 . . Sender. . . . . . . . . . 212612 . . . . . . . . . . . . . . . . . . . . . . 72 . 1 . . . . . . . . . . . . 189908 . Air Cleaner Safety . . . . . . . . 172071 . . . . . 110c . 2 . . . . 1 . . . . . . . . . Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . .709odx. Switch. . . . Cover Assy. . . . . . . 83 . . . . . . 1 . . . . . .5x 25 Hex Hd−pln 8. . . . . . . . . Cable. . . . . . . . .6 Ft. . . . . . . . . . . . . . . Oil Drain 32. 1 . . . . . .750 High Rbr 50 Duro W/O . . . . . . . . . . . . . . .500 Id X . . . . . . . . . . . . . . . . Mtg Engine . . . . . . . . . . . 2 . Screw. Mkgs. . . . . . . . . . . . . . . . . 1 . . . . . . 80 . 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145054 . . 1 . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Dust Ejector. . . 1 . . . . . . . . . . . . 1 . . . 1 . . Bracket. . . . . . . . . . . . . . . . . Door 1. . . . 1 . . . 90 . . . . . . . . . . . . . . . . . . . . . 181572 . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190207 . . . . . . .402idx0. . . 86 . . . . . . . . .8 Pln . . . . . . . . . . . . . . . Ftg. Body. . . 124253 . . . . . . . . . . . . . . 1 . . Clamp. 2 . . . . . Clip. . 1 . . . . . . . . . . . . . .375 Rng . Valve. . . . Filter. . Bracket. . . Fuel Stand Pipe W/5/16 In Ftg (Supply) . 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . BATT . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 . . . . . . . . . . . . . . . Bat Pos 45 In Lg No 1 Awg W/Clamp & . . . . .O. . . . . . . . . . . . . . . . . . . Belt. Rocker . . . . 049026 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213670 . . . . . . . . . . . . . . . 197675 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut Retaining . . . . 197829 . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . Radiator Lower . . . . . . . . . . . . 213668 . . . . . . 87 . . . 213461 . . . Lock . . . . . . Air Cleaner . 213463 . . . . . . . . . . . . . . . . . . . . . Mtg Generator . . . . . Tank. . . . . . . . . . . . Drain Fuel 180 Deg Zinc Pld . . . . . . 213460 . . . 212611 . . . . . . . 62 . . 212617 . . . . . . . . . 1 . . . . . . . . 1 . . . . . . . . .656idx2. . . . 85 . . . . 217686 . . . . . . . 6 . . . . . . . . . . . . . . . 111352 . . 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mtg Generator . 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose. . . Cat Dsl Elec 3013c (1800) Series . . . . . . . 213266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .000 . . . . . 1 . . . . . . . . Washer. . . . . . . 56 . . . . . . . . . . . . Element. . . . . . .

Capacitor. . . . . . . . . . . . . 213483 . 103 . . . . . . . . . . . . . . . . . . . . . . 105 . . . . . . . . . . . . . . CT1 . . . . Label. . Bracket. . . 1 + When ordering a component originally displaying a precautionary label. . . . . . . 104 . . . . . . . Bracket. . 1 . . . . . . . . . . . . Shld Stl Sch . . . . . . . . . . . . . . . . . . . . . . . +226104 . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . Capacitor Assy. . . . . Figure 13-3 Front Panel Assembly . . 1 . . Washer. . . . . . . . . . . . ♦Optional To maintain the factory original performance of your equipment. . . . . Screw. . 1 . . . . . . . . 218460 . . . . .437 X . . T1 . . . . . . . . Link. . . ♦230634 . . . . . . . 1 . 92 . . . 213490 . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . 213504 . . 1 . . 101 . . . . . . . . 102 . . . . . . . . . 1 . . . . . . . . . . . . 226163 . . . . . . . Warning General Precautionary . . . . . 172661 . . . . . . . . . . . . . . . . 1 . . TE1 . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . Kit. . . . . . 1 . . . . . . . . . . . . . . . Cer Disc . . . . . . . . 1 . . . . . ♦230828 . . . Block. 1 . . . . Solenoid Assy (consisting of) .250−20 X . . . . . . . . . 93 . . . . . 071731 . . . . 95 . . . . . . . Description Figure 13-1. . Rating Card Ce 907281 (CC/CV Model) . . . . Figure 13-2. . . . . . . . . . . . . . . 1 .0047 Uf 3000 Vdc W/Terms . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . .Elctlt 16000 Uf 60 Vdc Can 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . 226422 . . . . . 1 . 1 . . . .187t Stl Pld . . . . . . . . . . 109 .500 Shld . WW Tap 300 W 40 Ohm . . Solenoid. . 1 . . . . . . . . . 3 . . Label. . . . . . . . . . . . . . . . . . . (CC/CV Model) (Includes) . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . Label. . . . . . . . . . . . . . . . 213506 . . . . . . . . . . . Panel. . . . . . Hold−Down Fuel Tank (Not Shown) . . . . . . . . . . . 213027 . . . Throttle . . . . . . . . . . . . OM-4435 Page 68 . Current . . . . . . . . 1 . * Recommended Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 173734 . 223378 . Front . . . . Beam Support . . . . . . . . . . . . . . . . . . . . . . . TS1 . Idle. . . . . 99 . . . . . . . . . . . . . . . . . . . . . . . . . Tray. . Upright. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213500 . . . . . . . . C11 . 163535 . . . . . . . . 226150 . . . . . . . . Dia. . C10 . . . . . . . . . . . . 1 . Flat . . . Stud Connection 6 Position . . . . . . . . . . . . Capacitor. . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 91 . . . . . . . . . . . . . Support. . . . . . . Bus Bar. . . . . . . . . . . . . . . . . . . . . . . . Main Assembly (Continued) Quantity . . . . . . . 500−13x3. . . . . . . . . . . . . . . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . 94 . . . . . . . . . . . . . . Xfmr. . . . . . Engine Rh . . . 220887 . . . . . . . . . . . . . . .656idx2. . . . . . . . . . . . . . . . . . . . . . . . . Bracket. . 1 .250odx. . . . . 2 . . . . . . . . . . . . . . Model and serial number required when ordering parts from your local distributor. . . . . . . . . . . 1 . . . . . . . .Capacitor Bank Negative . . . . . . . . . . . . 98 . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Lb Spring . . ♦230830 . . . Bus Bar. . . . . . . . . . 213600 . . . . . . . . ♦105370 . . . . . . . . . . . . . . . . . . . . . . . . 108 . . . . . . . . . . . . . . . . . . . 217054 . . . 107 . . . . . . . . . . . . . . . . Isolation . . . . . . . . . . . . . . . . . . . . . . . . 213489 . Mkgs. . . . . . . . . . . . . . . . . . . . . . . . Brkt. . . . . . . . . 96 . . . . . . . . . . . 1 . . .Capacitor Bank Positive . . . . . . . . . . . . . . . use only Manufacturer’s Suggested Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214742 .00 Hex Flange−hd Gr8 Pln . . . . . . . . . . . . . . . . . . . . 213485 . . Rating Card Ce 907143 (CC Model) .75 Dia . . . . . . . Arm. . . . . . . . . . . . . . . . . . . . . . Ce Sound Power Level 96db . . ♦198109 . . . . . . . . . . . . . 220955 . . . . . . . . . . 1 . . Support. . . . . . R3 . 6 . . . . . . . . 213464 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 . . . Linkage. . . . . . . . Throttle W/4−8. . . . . . . Mtg Solenoid Idle . . . . . . Reactor&Rectifier . . . . . . . . . . Battery Locator (In Base − Not Shown) . . . ♦198018 . Engine Lh . . . . Front Access . . 99 . . Jumper . . . ♦230637 . . . . . . . . . . . Label. . . . . . . . . . 100 . . . . . . . . . . . . Throttle Solenoid . . Part No. . . . . . . . . . . . . . . . Resistor. . . . . . . . . . . . . . . . Xfmr. . . . . . . . . . . . . . . . the label should also be ordered. . . . . . . . . . . . . . . 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Item No. . . . . . . . . . . . . . Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . .

.. . . . . . ... . 214762 . . . . Description Quantity Figure 13-2. . . . Boot. . . . S4 . . .43 .. . . Panel. . . Lock. . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 OM-4435 Page 69 . . . PC6 . . . . . . . R1 .. . . 193118 . . . . . .. . . . . . Hardware is common and not available unless listed. . . . . .. Pointer 2. . . . Pointer . . . .. . . . . . . . . .. . Connector/Receptacle . Dia. . . . . . . . . . . .312/. .. . . . 214760 . 083432 . . . . . Tgl Spst 3a 250v Off−none−(On) Spd Term . PC2 . .. . . . Circuit Breaker Clear Hex Nut . . . . . . . . . . Circuit Card Assy. .. . . . . . . . . . . . . . .) . . . . . . . . . ♦214660 ... .. . . . . . . . . . . . Front Engine/Weld Control .. . . . . . . . . .375−32 X . . . CB8 . .. . . . . . . . . . . . .. .. . . .. . . . . . 072590 . . . . . .. . . . . Nameplate. . Switch. Man Reset 1p 10a 250vac Frict . .. . . . . . . . . Circuit Card Assy. . . . . . . . . . . . . .. Conn. . . . . . . . . . . . . . . . . . . . .375w/Post&lock . . . . . . Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . .250 Id W/Set Screwsplstc . . .. . . . . Pc Card . . . . . . Display W/Program . . . . . .. . . . . . . . 10 9 13 25 24 26 27 11 12 8 Wiring harnesses are listed at the end of parts section. . . . . . . . . . . Panel. . . . . . .250 Id W/Set Screwsplstc . . . .. R2 . . 097922 . . .. . . . . .. . . . . .. . . . . . .. . . Mkgs. .. . . . . . . . . . . . .. . . . . . . .. . . . . . . . . . . Meter Hole Cover . .. ... . . . . . . .. . . . . .. . . . . Switch. . . . . . . .. . . 7 14 15 23 22 28 6 16 20 5 4 1 2 3 41 40 39 17 18 19 21 29 34 33 31 32 30 38 36 37 35 804 011−B Figure 13-2.. . . . .. . . . Panel. . . . . . .. . . . . . . 214864 . Front w/Components (CC Model) Item No. . . . . . . Part No. . . . . . . . .. Bracket. . .. . . . . . . .. . . . . . . . . . . . . .875 Dia X . . . . . . . . . . . . . .. ... . . Enclosure. . . . . Pot. . . . . . . Rotary 12 Posn 1p 200ma 28vdc W/Resistors . . .375 Dia X . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . .. . Supplementary Pro. . . . 021467 . . .. . . . 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 . . . .. . . . . . . . . . . . . . Front w/Components (CC Model) (Figure 13-1 Item 97 ) . .. . . . . . 170391 . . . . ♦214543 . Cp Flat 1t 2. . . . . . Shaft Pot . . . . . . 097926 . .. . . . . . .250 Dia Shaft Tall . . . . . . . . 206795 . . . . . . . . . . . 229949 . Control (Order By Model & Serial No. . . . . . Circuit Card Assy . .. . W 1k Ohm Linear . . . . . Knob. . . . . . . . . . Knob. . . ♦134201 . . . Stand−off Support. . .

. . . 212436 . . . . . . . . ELCB1 . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010381 . . . . . . . . . . . . . . .640odx. . . . . . . .. . . . .875 Lg . . . . . . . . Mkgs. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . Brs . . . .. .. . . . . . . . . . . ... . C11.. . . . . . . . . .19h Brs . . .. . . . . . . . . . .. . . . . . . . . . . . . . No 6−32 X . . Supplementary Pro. . . . . . . .. . . . . 151981 . . . . . . . . . . . . . .. . . .. . Description Quantity Figure 13-2. . 224428 . . . . 1 1 2 2 1 1 1 1 1 2 1 1 1 4 1 4 3 2 2 1 2 2 2 1 1 1 ♦Optional + When ordering a component originally displaying a precautionary label. . . Boot. . . . . Elcb 30a 220v 0. . . .. . . . . . . .Item No. . . OM-4435 Page 70 . . . . . . . . . .. . . . . . . . . . . .. .. ... . . . . .. . . . ... . . . . . . . . Panel. Front w/Components (CC Model) (Continued) . . . . .Str 2p3w 32a 220v Flange Mtg .) . . . . . . . . . . . . . . . ... .. . . . . . . . . . . . . . 601836 . . . . . Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . .. . . . . . . . . . .. . . . Rcpt.. . . . . .. . . . . . . . . . . . FUEL/HM . . . . . . Panel. . Boot. . . . .. . . . . . . . . . . . . . . . .. . . . . .. Elcb 20a 220v 0. . . . . . . Terminal. . . . . . . 217054 . . . . . . . Terminal. . S1 .. . . . . . . . . . . . . . . . . . Capacitor. . . Pwr Output Black . . . . . . . . . . 214768 . . . . . . . . .. . To maintain the factory original performance of your equipment. .. . . Generic Output Stud . . . . . . . . .. . . . . . . .. . . . . . . .. 186621 . . .. . . Power CE . use only Manufacturer’s Suggested Replacement Parts. Flat .. . . . . . ..257idx0. . .. . . . . . . . .. . . . . . . . . . . . . . . . . .. . Switch. . Part No. . . . . . . .. . .0047 Uf 3000 Vdc W/Terms . . . . Receptacle W/Gasket . . . . . .. . .030a Trip . . . . . . . . . . . . . Rectifier . .. Pwr Output Red . . . . . . . . . . .. Cer Disc . . . . . . . . . . . .. . Toggle Switch Lever . . .. . . . . .. . . . . . . . . . . .. . . . . Dia. . . . . . 083030 .. . ELCB2 . . . . . . . .750 W/Hex Collar . Cer Disc . .031t Brs . . . . . . . . . . . . . . . . . 039046 . . . . . . . . . . . . . RC11 . . GRD . .. . . . . . . . . . . .. . . .. .. . . . . .. . . . . . . . . . . . . . . . . . 14 . . . . . . . . . Washer. 12 . . . . . 209056 . . . . . 176355 . 206795 ... .. . . . . . . . . . . . . . Connector. . . 021385 . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .250 Hex Al Fem .. . . . . .. . . Capacitor. . . . . . . . Nameplate. . Fuel Elec/Hour Meter . . . . .. . . . . 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 . . . . . Gauge. . . . . . . . . . .. . . . . . . . . . . . Ignition 4 Position (Includes Knob) . . . . . . . . Boot. .. ... . . . . . . RC12 . . . . . . . . . .. .. . . . . . . .250−20 X 1. . .. . Output Stud . . . . . . .. . . . . 222992 . . . . . . . .. . . Washer. . . . . .. . . . . . . . . . 010915 . . . GFCI1 .. . Circuit Breaker. . . . 222991 . Nut. . . . . . . . 093996 . . Stand−off. . . . . . . .. .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . .030a Trip . . . . . . . . . . . . . . . . . . . . . . . . . 180735 . . . . 250−20 . . . . . . 156831 . . . Stud. . . . . . Weld Terminal (Order By Model & Serial No. . . . . . Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . CB5 . . . . . . . Generator Power (Order By Model & Serial No. . . 039047 . . . . . . . . . . . . Spacer. . 128750 . . Man Reset 1p 20a 250vac Frict . . . . . . . . .. . . . . . C13. .. . . . .. . . . . . . . . . . . Cover. . . . . Circuit Breaker.. . . . . . . Rcpt. . . .. . .. . . . . . 144844 . . . . . Model and serial number required when ordering parts from your local distributor. . 181169 . .. . . . ... . . . the label should also be ordered. . . . .. . .50hex . . . .. . . . . . . . . . . . . . . . . . .. .. Nameplate. . . . . . . . . . . . . . Str 2p3w 16a 220v Flange Mtg . . . . . .. . . .. .. . . . . .. .) . . . . Circuit Breaker Clear Hex Nut . Rcpt. .. . . . . . .

. . . Display W/Program . . . .. . . . . . .. . . . . . . . ♦134201 . . . . . .. . . . . . .250 Id W/Set Screwsplstc . . .. . . . . . . . . . . . R2 . . . .. . . 097922 . 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 .. . . . . Supplementary Pro. . . . .. . . . .375w/Post&lock . . . . R1 . . . . . . . . . . . . . . . .. . . . .. . . . . ♦214543 . . . . Tgl Spst 3a 250v Off−none−(On) Spd Term . . . .43 . . . 170391 .. . . . . . . . . . . . . . Switch. .. . . . . . . . . . . W 1k Ohm Linear . 8 7 14 15 6 16 5 4 1 2 3 37 36 35 17 18 22 19 21 20 23 24 25 26 30 31 34 33 32 28 29 27 804 443-A Figure 13-3. . Wiring harnesses are listed at the end of parts section. . . . . . . . . . .. . . . . . . . . . Circuit Card Assy . . . .375−32 X . . . 214762 . . . . . .. . . . . . . . . . . . Bracket. . . . . . ..10 9 13 11 12 . . . .. . . .375 Dia X . . . . . . Circuit Card Assy. . . Cp Flat 1t 2. . Hardware is common and not available unless listed. . . . . . . . .. . . 083432 . . . . . 214864 . . . . . . . . . .. . Conn. . . . .. . . . . . . Rotary 12 Posn 1p 200ma 28vdc W/Resistors .875 Dia X . . . . . .. Knob. . . .. . . . .. . . . . .250 Dia Shaft Tall . . . . . . . . Panel. . . . . . . PC6 . . . . . . . . . . . . . . . . . . ♦214660 . . . . . . . . . . . . ... . Control (Order By Model & Serial No. . 206795 . . . . . . . . . . . . . . . .. . . . . . . . . Front w/Components (CC/CV Model) Item No. . . . . S4 . . .. . . . Description Quantity Figure 13-2. .250 Id W/Set Screwsplstc . . . . Pot. . . . . Front Engine/Weld Control . . . . . . .. . . .. . . . . . . . . . Lock. . . . . . Circuit Card Assy. . . . . . . . . .. . . . . . . . . . . . . .. . . . . .. . .. . . 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 OM-4435 Page 71 .. 072590 . . . . . . . Circuit Breaker Clear Hex Nut . Enclosure. . Pc Card .. Pointer . . Mkgs. . . . . . .. . . . . . . Nameplate. 097926 . . . . . . . . 021467 .. . . . . . . . .. .. .. . . Part No. . . . .. . . . . . . . . . . . . . . . . . . . . Shaft Pot . Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . Boot.. Panel. . . . .. . . . . . PC2 .. . 229949 . . . . . Front w/Components (CC/CV Model) (Figure 13-1 Item 97 ) . . . . . . . .. . . . .. . 193118 . . . . . . .. . .. . . . . . . . . 214760 . . . . . . . . . .. ..) ... .. . . . . . . . . . Knob.. . . . .. . . CB8 . . Connector/Receptacle . . Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . .312/. . . . . . . . . . . . . . . Pointer 2. Switch. . . . . . . . . . Meter Hole Cover . . . .. . . .. Dia. . . . . Panel. Stand−off Support. . . . . . . . . . .

. . . . . . .. . . . . . . . . . . . . . . .640odx. C13. .19h Brs . . . . Circuit Breaker. . . OM-4435 Page 72 . . . ELCB2 . . ..Str 2p3w 32a 130v Flange Mtg . . . . . . . . . . . . . . . . . . . . . 083030 . . .. . . .. .. . . . . . . . . . Dia. . . . . 224428 . . .. . . . . . . .. . . . .. . . . . . . . Output Stud . . . . . . .. . . . . . . . . . . . . Connector. . . . . . .. . . . . . . Generator Power (Order By Model & Serial No. . . . .. . Description Quantity Figure 13-2. . . . .. . . 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 . . . . . . . . . . . . . .030a Trip . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . Model and serial number required when ordering parts from your local distributor. . . 010915 . . . . . . . . .. . . . . . . . . . . . . . Nameplate. .. . . . . . . . . . . . . . . . . Washer. . . . . 144844 . . . . . .. . . . . . . Cer Disc .. . . . . . .. .. RC12 . . .. . . . . 1 1 2 2 1 1 1 1 1 1 4 1 4 3 2 1 2 2 2 1 1 1 ♦Optional + When ordering a component originally displaying a precautionary label. . . ... . . . Generic Output Stud . .031t Brs . . . .. .. . .. . . . . . . 214768 . Boot. . . . . . 128750 .. . . . .. . . . . . . . . . ... . . . . . . . .257idx0. . Switch. . . . . . . . .. . . . . . . . Power CE . . . . . To maintain the factory original performance of your equipment. . . . . . . . . . S1 . . . . . . . . . . . . . Mkgs.. . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . .. . . . . . . . .. . RC11 . . .. . . . . . . . . . . . .. 250−20 . . . . 039046 .. . .) . Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flat . . . . . . . Panel. . . .. . . . . . . 010381 .250 Hex Al Fem . . .. . . . . . . .1 Uf 500 Vdc W/Terms . . . . . Pwr Output Black . . . . . . . . . . . . . . . . . . . 601836 . . GRD . . . .. . . . .. . . . . . . . . . . 021385 . . . . . . . .. . . . . Ignition 4 Position (Includes Knob) . 181169 . . . .. . . No 6−32 X . . . . . . . . . . . .. . . . . FUEL/HM .. ..) .... . . ... . .. . . . . . . . Part No. . . . . . . . Spacer. . . . .. 209056 .. . . . . . . Str 2p3w 16a 130v Flange Mtg . . . . . . . . . . . . . . Rcpt. . . . . .750 W/Hex Collar . . . Panel. . . . .Item No. . .030a Trip . . . . . . . . . . . . . . . . . .. . ... . ... . . . . . . . .. . Boot.. .. . Brs . . . . . . . Fuel Elec/Hour Meter . . . . . . . .. . . .. . . . . . 212436 . . . . . . . . . . . . . . . ELCB1 . . . .875 Lg . . . . . . . . .. . . 14 .. . .. . . . . . . . .. . . . .. .. . . .. ... . . . . . . . . . . . . . . . 222991 . . . . . . . . . . . . . . . . the label should also be ordered. . Stud. . . . . . . . . . Washer. . . .. . . . . . Pwr Output Red . . . . . . . . . . . . Gauge. . . . . . . . . . . . . . Terminal. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. Rectifier . . . . . Capacitor. . . . . Circuit Breaker. . . . . . . .. .50hex . . . . . . . . . . . . . use only Manufacturer’s Suggested Replacement Parts. . . . . . . . . . . 186621 . . . . . . . . Output Stud . . . 180735 . . Elcb 30a 220v 0. . . Rcpt. . . . . . . . Stand−off.. . Receptacle W/Gasket . . . . Elcb 20a 220v 0. . . . . . . . . . . .. . . . . . . . .. . . . . . Terminal. . . . . . . . . . . . . . . . . . Nut. . . . . .. . . . . . . . .. . . 222992 . .. . . . . . . . . . . . . . . . . 173555 . . . 173556 . . . .250−20 X 1. . . ... . ... . 039047 . . . . . . . . . Nameplate. . . . . Front w/Components (CC/CV Model) (Continued) . . . . . . Weld Terminal (Order By Model & Serial No. . . . . . Cover. ..

. . . . . . . . Module. . ♦090104 .. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 .. . Man Reset 1p 10a 250vac Frict . . . . . . . . . R4 .. . . . . . . . .. . . . . . . . . . . . . . . . . . ♦230635 . . . .. . . . . . . . . . Relay. . . . . Model and serial number required when ordering parts from your local distributor. .. . . . . . Hardware is common and not available unless listed. ... Circuit Breaker... . .. . . . 2 5 6 7 8 1 10 9 11 12 13 14 15 803 689-D Figure 13-4. . . . Relay. . . . . . . . . CB9 . . . . . . .. . . . . . . 190374 . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . SR3 . . . . . . . . . . . . Auto Reset 12vdc 8 Amp .. Mtg Components . . . . use only Manufacturer’s Suggested Replacement Parts. . . . . . . . CR2 . . . . . . . ♦214761 . . Fuse. .. . . Pull To Idle . Control Panel Item No. . . .. Integ Bridge 40.. . . .. Relay. . . . 4 3 Wirng harnesses are listed at the end of parts section. . . . . . . Holder. . . . . . . .. .. . . . . . . . . . . SR1. Auto Reset 12vdc 40 Amp . Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . Fuse Mintr . . . . . . . 083432 . . .. . . . . Integ Bridge 40. . . . . . . . . . . .. . . ♦035704 .. . .250 Panel Mtg . . .. . . . . To maintain the factory original performance of your equipment. . . . . . . . Frict 250x032 Uninsul Male .. . . . CR1 . . . OM-4435 Page 73 . . . . . . . . . . . . . .250 X 1.130 Stud Mtg 3pr . Circuit Breaker.. . . . . . . . . . .. . . Dia. ... . . Rectifier. . . . . . . Term. F1 . . . 197325 . 214876 . . . . . . . . . PC5 . the label should also be ordered. . . . . . . . . 1 2 1 1 1 1 1 1 1 1 1 2 1 2 1 ♦Optional + When ordering a component originally displaying a precautionary label. 046432 . . . . . . . . . . . . . . . . . Description Quantity Figure 13-4. . . . .. . Mintr Cer Slo−blo 10. . . . 035704 .. . . . . . . . . .. . Amp 800v . SR2 . .. . 217335 .. . . . . .. . . . 220981 . . . . . . . . . . . . . .. . . . . . . CR4 . . . . . . . . . . . Bracket. . . . . . . Amp 800v . . . . . Encl 12vdc Dpst−no 25a 6pin Flange . . .. . Part No. . . . . . . Mkgs. . . . . . . . . CB3 . . . . . . . . . .. 129524 . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . CB1 . . Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg .. . .. . . . Rectifier. Resistor Board . . 085874 . . . . . . . . . .. .. . . . 223710 . . . . . . Relay. . . Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . CR3 . . .. . . . . . . . . . Control Panel (Figure 13-1 Item 2) . . . CB2.. . .. . . . . . . . . . . . . . . Amp 250 Volt . . . . . . . . . . . . .

Generator 4 Pole .. Generator Item No. . .. . . . . .. . . .. .. .. .... . . .. .. . . Stator... . . . .. . .078t Stl Pld Split.. . . .. . . . . . .. . . . . . . . . Brush Elect . . . . . . .. . .. . .586odx. . Holder. . . ... Cap. . . .... . . . Mkgs.. . . . .. .25x 25 Hex Hd−pln 8. . . . . . . . .. . . .. . . . . . ...... Screw. . ... . ... . . .. . .. . . . .. . .. . . . .. . . . . . . . To maintain the factory original performance of your equipment.. .. . . .. .. . . . ...50 Hex Hd−slt Stl Pld Sq Cone Sems . .. Washer. ... . . . . .. . . . . . .. . . . ... . . .. . . .. . . Engine Machined Cat 3013c . . . . . . 212474 053390 192600 159918 212126 602211 192686 602211 192686 212641 219920 160943 167788 218552 047879 161306 126984 005614 125548 158832 ... . ... Stl . . . . . . . . . . . . Bearing. . . .. . .. .. .. . . . .. .... . Generator . 1 1 1 1 1 6 6 6 6 4 1 1 4 1 1 2 2 2 1 2 Quantity + When ordering a component originally displaying a precautionary label. . . . . ... . . ... . .. . .. . .. . . . . . . . . . ... . . . .. . . . . . . . . . . . Brush w/Spring . .... .. .. . . M 8−1.. . . . .. . . . ... . .. . . .. .312 .. . . . .. . . .34h Stl Pld Sem Cone Wshr.. .. Brush . . . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 .. . . . . . . . . . . . . . . ... . ... ... . .. . .. . . . . . . . .. . ... .. ... . . Ball Rdl Sgl Row 1. . .. . . . . .. .078t Stl Pld Split... . . . ... . .. . .. . . . Lock ... .. . . . . .. .. . . Hardware is common and not available unless listed.. ... .. .. . Assembly 2 Pole (Includes) ... . . . . . . Brushholder .. . .6 . . .. .. . . OM-4435 Page 74 . . . . . .. . . . . . ... Lock . . . . . . . . .. .. .375−16 1....... .. . ... Generator 4 Pole (Includes) . . . .. .625x 19. . . . . .. . . ... . . . .. . . . . . . ..370 X 2. . . . . . . . . . Dia.. . . . . ... . . the label should also be ordered. .. M 8−1. .. .. .. . . . . . . . .. .. . . . . . . . . Fan. . . .... . . . . . . .. . . . Stud. .. . . . . . Wiring harnesses are listed at the end of parts section. .. .. . . .. . .. Description Figure 13-5... .. . . ... . Nut. . . ... . . .. . . Rotor. . . . .. . Screw. . . . . . . . . . . .. . . . .. . . . . . . . . .. . .318idx0.. . .. .. . . .. .. . ... . . Adapter. . . . .. . . . . . .. . . . . .. . . . . .... . ... . . .. .. . Washer. . .... .88d . .. . Part No. . . .. .. . . . . . ... . . . .. .. . Screw. . . .. ... . . ...000 . . . . .. .. . . . .. . .. . ..8 Pld Din933 . ROTOR .. . . . . . . . 1 4 3 5 6 7 2 9 10 8 11 12 13 14 20 19 18 17 16 15 803 686-A Figure 13-5. . . . .. .. . . .. . . . . . . . . Holder. . .. . . . .. . . . . . . ... . . . . .... . . use only Manufacturer’s Suggested Replacement Parts. . . .. .. .. .. 010−32x . . . . . . . .. .56hex .. . . ..318idx0. . . . . . . . ... .. . . . .. . . . . Retaining Brushholder 2 Brushes . . . . . . . . . . . 375−16 . . .830 X . . . .25x 25 Hex Hd−pln 8. . . . Fan . . . . . . Model and serial number required when ordering parts from your local distributor. Brush.. ... Bar. ... . . . . . ... . . . . .586odx... . . Baffle... .. .. ... . . . .. Generator (Figure 13-1 Item 71) .. .. .. . . . .. Endbell . .. . STATOR . . .. .. . . .312 . . . . . . . .. . . . . . . . .. . . . . . .. . .. . .. .. . .. .. ... . . . . . . . . .. . . . . .8 Pld Din933 . . .

. .. . . . . . . . . .. . . .. . . . 1 1 1 3 1 3 1 4 Quantity To maintain the factory original performance of your equipment.. C1−6 . . . . . . . . . . . . . . . .. . . ... TH1 .. .. .. .. . Ntc 30k Ohm @ 25 Deg C 8. . . .. . . . .. . . . . . . .. . . . .. . . . . 2 1 3 4 5 6 804 010−A Figure 13-6. .. . . . . . . .. Part No. . . . . . .. . . . . . .. . . . ... .. . Rectifier. . . . Insulator. .. . . . . . . . . . Capacitor Assy . . . Thyristor. . . . .... . .. . . . . . . .. . 217082 211984 212601 196760 217085 215611 213930 181853 .. . Screw (For Mounting Rectifier) . . . Heat Sink . .. . . . . . .. . Wiring harnesses are listed at the end of parts section. . . . . .. . . . . . . . . . . . . .. . . . . Thermistor. . . . . .. . . 2 . . . .. .. . . . . . . . . .. . . . . . .. . . . . . . . . .. . . 5 . . . . .. . . . .. . Insulator. . . . . . . . . . OM-4435 Page 75 . 6 . . . . . . .5in Lead . . . . .. . Bus Bar. .. Mkgs.... .. . . .. . . . . . . . . . . . 4 . . .2. . . . . 1 . Rectifier Assembly For CC Models Item No. . Scr Module 190a 400v Dual .. . ... . . .. . . .. . . .. . .. . . use only Manufacturer’s Suggested Replacement Parts. . . .3 . . Rectifier .. . . . . . MOD1. . . Model and serial number required when ordering parts from your local distributor. . . . ... . .. . . . .. . . . . . .. . . . . . . . . Dia. . . Rectifier Assembly (Figure 13-1 Item 4) . . . ..... . .. . . .. . .. .. . . . 3 .. . .. . . . . . .. . .. . . . Description Figure 13-6. . . . ... .. .. . Hardware is common and not available unless listed. . . . . . . ... . .. . .. Rectifier . . . . . . . .. .. . Assembly (Includes) . ..

. . . Rectifier . . . . . . 10 . . . . 7 . . .. .. . . . . . . . . . . . . . . . . ... 3 . C7. . .. . . . . . . . . .. . . . . . Insulator. . .2. . . . Rectifier ... . . . . . . . . .. . . . . .. .. . . . . . . . . . . . .. . . . . . . ... . . . . . . .. 2 . . . ... .. Bus Bar... . .. . . . .. . . . . . . . . . Hardware is common and not available unless listed. . .. . .. . . .. . . . Rectifier . . . . . . . .. . . . . . . . . . . . . . .. . . . .. . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . Description Figure 13-6. . . . Rectifier Assembly For CC/CV Models Item No. 217081 211984 218296 218292 212602 212639 212601 213930 215611 048420 217085 181853 . . . .. 9 . . . . . .5.. . . . . . 8 . . . .. . . . .. . . .. .. . . . . . . . . . . . . .... . . . . . .. .. . . . .9 .. . . Rectifier Assembly (Figure 13-1 Item 4) . . . . . . . . . . Bus Bar. .. . . . . . .. . . .. . . . . . . . . .. Kit. .. .. . . . . . .8. . . . . . . . .. . . 3 2 6 1 7 10 8 5 4 9 803 685-A Figure 13-7. . . Part No.. .. . . . Module SCR . .. . . . . .01 Uf 1000 Vdc W/Terms . . . .. . Dia. . . . . . . Module SCR . . . . . . . . . 5 .. . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . ... . 1 . MOD4. . . . . MOD1. . . . . . . . . . . . .6 .. . . . . . .. . . . . Ntc 30k Ohm @ 25 Deg C 8.. . . . . . . .. . . . . . . . ... . .. Heat Sink .. . . . . . . . Screw (For Mounting Rectifier) .. . . . . . . . . .. .. . . .. . . . . . . . . . . Rectifier.. . . . Wirng harnesses are listed at the end of parts section. .. .. ..5in Lead . . . Rectifier .. . . . ... . . . . . . . Capacitor. . . . . . ... . . . . . . . . . . . use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.. OM-4435 Page 76 . Insulator. Cer Disc ... . . . . . . . . . . . . . . . . . . .. . Mkgs. . . . . . . . . . . ... . . . . 1 1 3 3 1 3 1 1 3 3 1 4 Quantity To maintain the factory original performance of your equipment. . . . . . . . 6 . . . . Assembly (Includes) . . . . . . . . . Bus Bar. . . . . . 4 . . . Capacitor Assy . .. .. . .. . .. .... . . . . . . . . . .. . . . . . .. . . . . . . . .3 . . . .. . . . TH1 . . .. . . . . . . C1−6 . Thermistor. . . .. .. . . . . . . .. Kit. .

. . . . . .. . . . . . . . . . . . . . . .. . ... . . . .. . . . . . . . Switch. . . . . . . . . . . . . . . . .. . . . . . .. .. . Harness. . . . . . . . . . . . . . . .. . . . . . .. . . . . . . .. . .. . .. . . . . . . .. . . . . . Part No. . .. . . . . . . . . . . .. . .. PLG6 . 207716 .. . . . . . . . . Description Wiring Harnesses Quantity . . . .. .. . . . . . . . . ... .. . . . . . . . .. . . . . . . . . .. . . . . . 1 1 2 1 2 1 1 1 1 3 3 1 7 1 1 1 1 1 1 1 3 3 1 1 1 1 1 2 7 1 1 1 2 1 1 6 3 . Encl 12vdc Spst 70a 4pin Flange Mtg . . .. . . . . . .. . .. . . . .. . . .. . Deutsch 2p 1row Female Plug . . . . . . . . . Conn. S4 . . . . . . . . . Conn. . . . . . . Auto Reset 12vdc 40 Amp . . . . . . PLG10 .. . . . . . . . . . . . . . . .. . . . Rect Mini 045 4skt 2row Plug Cable Lkg . Conn. . .. . .. . .. .. . . .. ... . .. . . . . . ... CR2 . . . Socket. .. .. . . . . Pack Terminal Position Assurance(Lock) . .. . . Encl 6vdc Spst 35a/14vdc 5 Pin .. . . . . . . . . . ... .. . . . . .. . .. . .. . . .. . . .. .. .. PLG9 . . . . . . .. . .. .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . ... . . . . . . . Weld Control CE (Includes) . . . . .. . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . Conn. . . . . . . ... Rect Cinch 30 Pin ... . . . . . . . . . . . . Harness. Circuit Breaker.. . . . PLG9 . . . . . . .. . . . . . .. . . . . . . . . .. . . . . . . . .. . Conn. . .. . . . . . . . . . . . . . . .. . . .. . . . . PLG5 . . . . . .. . . .. CB2. . . . CB3 . .. . . . . . . . . . . .. . . . . . . ... . . . Mkgs. . . . Lem . . . Pack 4p 1row Female .. . . . . . .. . . . .. .. . . . . . . . Seal. . . . . .. . . . . . . ... ... . . . . . . . . . . . . . . . .. Faston Mini Polarized 2 Skt G2k2 . . . .. . .. . . . . . . . . . Rect Cinch 18 Pin . . .. . .. . . . . . . . .. . . .. . ... . . . . . . . . . . . . R4 . .. . . .. . . . . Seal. . Man Reset 1p 10a 250vac Frict . . .. .. . Deutsch Wedge Lock 12 Position . . . . . .. . . . . . . . CB1 . . . .. . . . . .. . . Harness. . . . . Conn. . . . . . . . . . . . . . . .. . Wire Univ 039 . . . . . . . . .. . . .. . . . . . . . . . . .Note Item No.. . .130 Stud Mtg 3pr . . . . . . . . .. ... . . . . . . . . . . . . . . . . . .. . SR2 . . Term... . For S1 . .. . . . . .. . . . . . . .. . . . . Seal. . . Integ Bridge 40. Conn. . . . .. . . . . . .. .. . . . . . .. . .. . . . . . . . . . . . . . .. . ... . For S1 . . . . . .. . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . .. . Conn.. . . . . .. . . circuit breakers) are also referenced elsewhere in this parts list.. . . . . . . . . . . . . Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S . . . . . . . . . Rect Cinch 18 Pin . . . .. . . . . . . . . Dia. . . . . .. .. . . . . . . . . . . . .. Some wiring harness components (switches. .. . .. . . . .. .. ... . . . . . . . . . . . . . ... . . . Conn.. . . . . . . . . . . . . ... .. . . . . . . . . . . . .. . . . . . . .. . . Conn. ... . .. Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . .. PLG7 . Amp 800v .. . . . . . . . .. . . . . ... . . . . . . . . . . .. . . . . . . . .. . .. . . . . . . . . . . ... . . . . . . Rect Univ 039 10p/S 2row Plug Cable Lkg . . Plug Univ 039 ... . .. . . . Cable. . . Conn. . . . PLG11 . . . ... . . . . . .. . . . . . . . . . .. . . Seal. . . Conn.. . . . .. Rect Univ 039 6p/S 3row Plug Cable Lkg Seal . .. . . .. . Harness. Tgl Spst 3a 250v Off−none−(On) Spd Term .. . . . . . Relay. . .. Conn. . ... . . . . . . . . .. . . .. . . ... .. Conn. . Seal. . . . . . . . . . . . . . . . . . . Conn. . . . .. Frict 250x032 Uninsul Male .. . .. . . . . . ... .. Deutsch Wedge Lock 2 Position . . . ... . . . PLG2 . ... .. . . . . . . .. . . . . Faston Mini Polarized 2 Skt G1k1 . . . . . . . . . . . . . . .. . . . . ... . . Receptacle Auxiliary Power . . . .. . . . . . . 193183 .. . . . . .. . relays.. . . . . . . . . . . . . . . . . . . . . . . .. . . . . 231122 021467 035704 190374 083432 197325 214876 217335 148850 212116 212117 214932 214933 214934 211292 211293 129524 221864 150316 214951 214933 214934 147992 193184 193183 215261 215262 215265 215343 113750 217000 215340 214933 . . . . . .. . . . . . . . . . . . PLG8 .. . . . . . . . .. . .. . . . . . . . . . . . . .. . . . .. . . .. . . . . . Purchase components separately or as part of the associated wiring harness.. . . . . .. . . . . . . . . . . . .. . . . . . . Relay 5 Pin . . .. . . . . . . .. .. . . . . . .. . . . . . . . .. . . . .. . . . . . . Plug Deutsch 12−16 Size .. . . . . .. Rectifier (Includes) . . .. . . .. . .. . .. . .. . .. . Engine CAT (Includes) .. . . . . . . . .. . . . . Plug Univ 039 . .. . . . . . . . .. . . . . . . . . . .. . . Rectifier. . . . .. . .. . 207718 .. .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. Conn. . . . .. .. . . . . . . . . . . . . . . .. .. . PLG1 . Wire Univ 039 . . . Seal.. .. CR3 . . . . . .. . .. . . . . Deutsch 12p 2row Female Plug . .. .. . . . Rect Univ 039 6p/S 3row Plug Cable Lkg . . . .. . . . . . . . .. . . . .. SR1. . .. . 217010 . . . . . . . . . . .. . . . . . . Conn. .. . . . . . . . . . . . . . . . ... . .. . . . . . . . . . . . . . . . .. . . .. . . Wire Univ 039 .. . . . Deutsch 12p 2row Female Plug .. . . Relay. . . . . . . . .. . . . . . . . . . . .. . . . . Conn. . .. . . . . .. . . . . . . . .. .. . . . 1 OM-4435 Page 77 . Circuit Breaker.. . . .... . 214982 / 214984 . . . . . .. . . .. . . .. .. Resistor Board . . . . .. . . .. . . . . . .. . . . ..

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or. 3. 6 Months — Batteries 90 Days — Parts * MIG Guns/TIG Torches and Subarc (SAW) Guns miller_warr 2007−01 . CUSTOM OF TRADE OR COURSE OF DEALING. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY. In Canada. and Legend models. if any. The expertise of the distributor and Miller is there to help you. Trailblazer. TO THE EXTENT PERMITTED BY LAW. GUARANTY OR REPRESENTATION AS TO PERFORMANCE. * * * * * * * * * Original main power rectifiers 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.B. where authorized in writing by Miller in appropriate cases. Consumable components. Miller must be notified in writing within thirty (30) days of such defect or failure. Some states in the U. Co.O. LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets.. 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. 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. INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE. or F. EXPRESS OR IMPLIED. These items are covered by the manufacturer’s warranty. every step of the way. WHETHER BASED ON CONTRACT. 2007 (Equipment with a serial number preface of “LH” or newer) Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Wisconsin. warrants to Non-Electronic Controls its original retail purchaser that new Miller equipment sold after * APT & SAF Model Plasma Cutting Torches the effective date of this limited warranty is free of defects in * Remote Controls material and workmanship at the time it is shipped by Miller. 2. but may vary from province to province.. (3) the reasonable cost of repair or replacement at an authorized Miller service station. Factory at Appleton. but manufactured by others. Your distributor also gives you . All warranty time periods start on the delivery date of the equipment to the original end-user purchaser. contactors. slip rings. This Limited Warranty provides specific legal rights. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT. or (2) replacement. INDIRECT. INCLUDING THE * Replacement Parts (No labor) WARRANTIES OF MERCHANTABILITY AND FITNESS.O. INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT). the limitations and exclusions set out above may not apply. Most replacement parts can be in your hands in 24 hours. reliable response you need.S. at a Miller authorized service facility as determined by Miller. legislation in some provinces provides for certain additional warranties or remedies other than as stated herein. such as engines or trade accessories. but may vary from state to state.) Bernard-Branded Mig Guns (No Labor) Weldcraft-Branded TIG Torches (No Labor) Subarc Wire Drive Assemblies 3 Years — Parts and Labor 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. indirect. at which time Miller will provide instructions on the warranty claim procedures to be followed. BUT FOR THIS PROVISION. Miller will repair or * Canvas Covers replace any warranted parts or components that fail due to such defects in material or workmanship. 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.B. or for a minimum of one year — whichever is greater. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. do not allow limitations of how long an implied warranty lasts. THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. or equipment that has been improperly installed. and relays are covered on Bobcat. Miller’s True Blue® Limited Warranty shall not apply to: 1.) Motor Driven Guns (w/exception of Spoolmate Spoolguns) Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources. 5.A. OPERATION OF LAW. 5 Years Parts — 3 Years Labor 2.. Coolers. such as contact tips. This warranty provides specific legal rights. TORT OR ANY OTHER LEGAL THEORY. Support Need fast answers to the tough welding questions? Contact your distributor. or equipment which has not had reasonable and necessary maintenance. and other rights may be available. brushes. or the exclusion of incidental. and below..Effective January 1. AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH. Wisconsin. improperly operated or misused based upon industry standards. Appleton. WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. cutting nozzles. 1 Year — Parts and Labor Unless Specified * * * * * * * * * * * * * * * * * * * 4. relays or parts that fail due to normal wear. 1. or equipment which has been used for operation outside of the specifications for the equipment. Cables. * Spoolmate Spoolguns Within the warranty periods listed below. and to the extent that they may not be waived. special or consequential damages. so the above limitation or exclusion may not apply to you. (Exception: brushes. This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. at Miller’s option: (1) repair.) Items furnished by Miller. Miller Electric Mfg. Equipment that has been modified by any party other than Miller. MIGHT ARISE BY IMPLICATION. the exclusive remedies shall be. Miller’s option of repair or replacement will be F. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Accessory (Kits) WARRANTIES. In the event of a warranty claim covered by this warranty. and other rights may be available. Service You always get the fast. slip rings. SPECIAL. 3.

Always provide Model Name and Serial/Style Number. 2007−01 . WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters − United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 www. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools. Videos. contact your distributor and/or equipment manufacturer’s Transportation Department.) For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you.millerwelds. Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www. An Illinois Tool Works Company 1635 West Spencer Street Appleton. PRINTED IN USA © 2007 Miller Electric Mfg.com or call 1-800-4-A-Miller Miller Electric Mfg.Owner’s Record Please complete and retain with your personal records. Model Name Purchase Date Distributor Address City State Zip Serial/Style Number (Date which equipment was delivered to original customer. Co.com Contact the Delivering Carrier to: File a claim for loss or damage during shipment.MillerWelds. For assistance in filing or settling claims. Co.