Equipment Manual 16

Equipment Manual 16
AVW – 300/301 Manual

Revision 3 – June 2011
COPYRIGHT  2011
BY
CHICAGO BRIDGE AND IRON CO.
All rights reserved
For questions or comments contact CCT: Jim Smith / CWT John Matthews
Issuing Authority: Manager Corporate Construction Technology
The information contained herein is proprietary and confidential. All documents remain the
property of Chicago Bridge and Iron Company and are to be used only in connection with the
performance of work by Chicago Bridge and Iron Company. This manual, and any information
contained herein, shall not be disclosed to any person other than employees of Chicago Bridge
and Iron Company or one of its affiliated companies. Reproduction in whole or part is expressly
forbidden.
Equipment Manual 16 CB&I Use Only - Confidential
AVW – 300/301 Manual Part REV
Revisions Page 1
Revision 3 – June 2011 – JAS
Changed tie off requirement for operator of AVW.

Reorganized Appendicies, moved to sections 2.4, 3.12, 3.13
Revision 2 – January 2010 – IH
Revision 1 – June 2009 – NS
Revision 0 – September 1994 – RJK
Original By: CB&I Date: 2007 Rev: 3 By: JAS Date: Jun 2011
AVW – 300/301 Manual Part TOC
Table of Contents Page 1
PART 1 INTRODUCTION – 2C300/301 SPECIFICATIONS

1.1 Safe Working Loads (SWL)
1.2 Overall Dimensions
1.3 Partial Component Product List
1.4 AVW Applications / Limitations
PART 2 RECEIVING AND SHIPPING

2.1 Packing List
2.2 Receiving and Setup
2.3 Shipping and Break Down
2.4 Detailed Load and Unload Instructions
PART 3 AVW SETUP AND OPERATION

3.1 2C300/301 Fall Prevention
3.2 Interconnection diagram - 2C300/301 AVW to CBI 800 / 801D
3.3 Welding Nozzle and Shoe Adjustments
3.4 AVW Control Settings
3.5 Travel Control Explanation
3.6 Shoe Selection and Care
3.7 Allowable Incline of Vertical Welds
3.8 Single Pass / Single Vee Welding
3.9 Set-up and Adjustments
3.10 Welding Start Sequence
3.11 Welding Stop Sequence
3.12 Conversions and Options
3.13 Front Shoe Sizes
PART 4 TROUBLESHOOTING
4.1 Trouble Shooting Weld Quality
4.2 Troubleshooting AVW Control
4.3 Troubleshooting T-Frame
4.4 General Troubleshooting Guide
PART 5 SUPPLIES
AVW – 300/301 Manual Part TOC
Table of Contents Page 2
5.1 Recommended Electrical Spare Parts

5.2 Recommended Hand Tool List
5.3 Miscellaneous Supplies List
APPENDIX A – FORMS
Checklists
Inspection Test Plans
APPENDIX B – APPLICABLE DRAWINGS
APPENDIX C – VENDOR DOCUMENTS
APPENDIX D – CB&I REFERENCE DOCUMENTS

High Wind Stabilizing – Construction Manual 13
Automatic Vertical Welding (AVW) Technique Requirements – CMS-830-15-GL-11021
APPENDIX E – JOINT FIT-UP / TECHNIQUE
APPENDIX F – WAREHOUSE SETUP
AVW – 300/301 Manual Part 1
Introduction Page 1
Part 1 Introduction – 2C300/301 Specifications
Although the AVW 301 is operationally the same as the AVW 300 several changes were made
to simplify fabrication and maintenance. While some of the main changes are listed here, a
more comprehensive can be found in Appendix I.
 The vertical chain drive has been redesigned to make the chain continuous.
 The wheel carriages have been redesigned to allow the wheels and axles to be removed
by dropping them down thru the bottom of the carriage by removing the bearing bolts.
 The AVW 301 is designed to be used for tanks 50‟ diameter and larger.
 The AVW 301 can be used on tanks down to 20‟ diameter for the FCAW process.
Contact CWT for set up of small diameter tanks for assistance.
1.1 Safe Working Loads (SWL)
Component SWL
Operator‟s Platform 2C300/301-20-A 500 lbs (225 kg)
Compression Arm Platform 2C301-123-A 250 lbs (112 kg)
DBI/SALA Load Arrestor 2C301-124-A 1100 lbs (500 kg)
Miller Safety Systems Lifeline Post 2C300-43-1 / 3 persons
2C301-43-1
Table 1-1
1.2 Overall Dimensions
Dimensions are given for a 16‟ vertical post for the AVW 301. See Figures 1a, 1b
and 1c.
Length 86” (2184mm)

Width 83” (2108mm)
Height 211” (5360mm)
Weight 2700 lbs (1227 kg)
Table 2a – For AVW 300

Width 83” (2108mm)
Height 211”-235” (5360mm-5970mm)
Weight 2850 lbs (1290kg)
Table 1-2 For AVW 301
Introduction Page 2
Figure 1a: 2C300 AVW Plan View – Equipment Footprint (outer dimensions are
approximately the same for an AVW 301 as well as the AVW 300)
Note: This manual has many attachments that must be printed separately. If you
need to see them and do not have access to them, please contact your local
warehouse, CCT, or CWT.
Introduction Page 3
Figure 1b: 2C300 AVW Elevation Figure 1c: 2C301 AVW Elevation
Introduction Page 4
1.3 Partial Component Product List
See Appendix C for complete detailed product information.
1. Koolant Kooler water pump/cooler

2. Proteus water flow switch
3. Miller Safety Systems lifeline post
4. Baldor BC154 motor control
5. Baldor DC motor
6. Lincoln LN-10 wire feeder
7. Gullco Oscillator and optional conversions (see local weld manager for
use and additional information)
8. Prototype Weather Shroud – Dwgs 2C301-150-169 (Contact CCT Before
Use)
1.4 AVW Applications / Limitations
Weld wire size - 30 – 60 lb coils

General Range: 0.035” to 1/8” Diameter
Standard applications: 3/32” dia. Lincoln NR-431 wire
Narrow Groove applications: 1/16” dia. Devasco wire
Material
Carbon Steel Acceptable
Low Alloy Unacceptable
Stainless Steel Acceptable (See Corp Welding)
% Nickel Unacceptable
Aluminum Unacceptable
Plate Sizes
1st Ring 5‟-0 (1829mm) minimum
Other rings w/ 16‟-0 post 12‟-0 (3660mm) maximum
Table 1-3
Receiving and Shipping Page 1
Part 2 Receiving and Shipping
A detailed set of packing and unpacking instructions can be found in section 2.4.
2.1 Packing List
(1) Automatic Vert Welder AVW-300/301.

(1) Compression Arm Platform
(1) Dimplex Water Cooler (if not mounted in MPS)
(1) Fume Extractor with hoses and parts in cardboard box (optional)
(1) Horizontal Drive Wheel Carriage mounted to floor (AVW 300 only)
(1) Tool Box with spare parts/small tools. (Tied to floor rail)
(1) Set (2 axles) of shipping "bogies" (carriages for mounting AVW to rails)
2.2 Receiving and Setup
1. The 2C300/301AVW ships in a 20‟ shipping container for assembly and setup. Plan
every step of the equipment setup. Ensure the proper lifting and rigging equipment is
used and that adequate space is provided for setup. Review Section 1 for equipment
weights.
2. Open the shipping container and fully extend the telescoping rails as shown in Figure 2a.
Ensure the rails have adequate footing.
3. Remove the horizontal drive wheel carriage, the compression arm platform, and the
Dimplex water cooler (AVW 300); or remove the compression arm platform and the
Dimplex water cooler (AVW 301).
Note: The water cooler may be pre-installed in the MPS.
4. Remove the shipping wheel locks shown in Figure 2e.

5. Pull the AVW 300/301 fully onto the telescoped rails as shown in Figure 2b. Install the
horizontal wheel carriage (AVW 300) or replace the short shipping brace on the
horizontal wheel carriage with the standard turnbuckle (AVW 301).
6. Remove the shipping post between the mast and compression arm, shown in Figure 2f.
Note: The compression arm hinge provides a flexible connection between the
compression arm and yoke/mast. The shipping post is used to support the compression
arm and mast, to prevent overloading the hydraulic cylinder (Figure 2d) at the hinge.
7. Hook up to an MPS and test all systems.
8. Adjust the mast position in the top clamp to correspond to the project shell plate height.
Assure mast clamping bolts are the correct type, size, installed correctly, and tightened.
Note that the AVW 301 has a special clamp which helps you to adjust the post position.
(See drawing 2C301-97 & Fig. 2-1 & Fig. 2-2) This clamp allows you to use the interior
spanner nuts to open the clamp to ease this adjustment. It is important to turn these
spanner nuts in (at least ¼” from the clamp lugs) before you start to tighten the clamp. It
is possible to tighten against the spanner nuts and assume the clamp is tight when in
fact it may not be. Tighten each bolt twice to assure the clamp is tight and then check
to make certain the spanner nuts are not in contact with the clamp. If they are close,
back them off again so it can be seen from the platform that these nuts are clearly not in
contact with the clamp. Hook off to the main lifting eye, lift the top end shipping carriage
(Figure 2c) off the rail, and remove the shipping carriage. Continue lifting until the AVW
300/301 is off the rails; remove the bottom shipping carriage (Figure 2d).
9. Extend the Miller Fall Protection post completely and install a minimum of two (2) self-
retracting lifeline devices (nylon webbing type preferred).
10. Hook off to the main lifting eye, lift the top end shipping carriage (Figure 2c) off the rail,
and remove the shipping carriage. Continue lifting until the AVW 300/301 is off the rails;
remove the bottom shipping carriage (Figure 2d).
11. Install the compression arm platform; make certain to install the locking bolts through the
platform support piece mark 2C301-96-4 and 2C301-123-4.
12. Install water pump in MPS carriage if not already there.
13. Set the AVW 300/301 on the tank shell. Take care not to damage the load arrestor.
Fig. 2-1 Clamping Action
Fig. 2-2 Prying / Opening Action
2.3 Shipping and Break Down
1. Plan every step of the equipment dismantling: Ensure the proper lifting and rigging
equipment is used, and that adequate space is provided for dismantling. Review
Section 1 for equipment weights.
2. Lift the AVW 300/301 off the tank shell.
3. Remove the compression arm platform and ladder extensions and install bottom
shipping carriage (Figure 2d) on the bottom clamp (The operator platform should be at
the bottom of the main post as in Figure 2b). Install the temporary post between the
compression arm and mast. Note: the compression arm hinge provides a flexible
connection between the compression and yoke/mast. The shipping post is used to
support the compression arm and mast to prevent overloading the hydraulic cylinder at
the hinge.
4. Fully extend the telescoping rails from the shipping container as shown in Figure 2a.
5. Lower the AVW 300/301 so the bottom shipping carriage is supported by the shipping
container rails. Install the top end shipping carriage (Figure 2c).
6. Lower the AVW 300/301 so the equipment is fully supported by the shipping rails;
remove the lifting equipment.
7. Tie the cable tray securely to the ladder and/or main post every 2 - 3 feet or use cable
tray shipping brace (if supplied) to prevent breakage.
8. Remove the horizontal wheel carriage (AVW 300 only). Replace horizontal drive wheel
adjustment turnbuckle with specified shipping brace (AVW 301 only)
9. Push the AVW 300/301 on rails until it is fully in the shipping container. Retract the rails
10. Install the shipping wheel locks.
11. Pack the horizontal drive wheel carriage (AVW 300), the compression arm platform, and
the Dimplex water cooler (if not left on MPS).
12. Fully secure the AVW and associated components using nylon ratchet straps provided.
Note: Container Interiors may Differ
Figure 2a: Shipping container rails Figure 2b: AVW on rails
Figure 2c: top carriage Figure 2d: bottom carriage
Figure 2e: shipping wheel lock Figure 2f: temporary shipping post
Figure 2g: water pump and air compressor Figure 2h: AVW 300 in container
2.4 Detailed Load and Unload Instructions
Note that the Shipping Container layout may differ form those pictured here, but the loading and
unloading procedures will remain the same.
Unloading
1. Remove any lose cables and hoses

2. Remove compression arm platform and water pump (if applicable)
Compression
Arm Platform
(Stowed)
3. Remove and save all ratchet straps/tie down keeping the AVW in the container
4. Remove wheel clamps
5. Extend rails until YELLOW paint just shows, adjust feet, and crib as necessary
6. Pull the AVW out of the container and lock wheels on rear (lower) bogie (if applicable).
7. Replace (and save) shipping brace on horizontal drive motor with supplied turnbuckle
(AVW 301) or reinstall the horizontal drive motor (AVW 300)
Shipping
Brace
Turn Buckle
8. Adjust the mast position in the top clamp to correspond to the project sell plate height.
9. Fully extend life line post
Sleeve Clamp For

Mast Adjustment
Life Line
Post
10. Install water pump in MPS (if not done at warehouse)
11. Hook up to an MPS and test all systems

12. Perform both an Open Circuit and Closed Circuit test as described below:
 Open Circuit Test
o Make all electrical connections between the AVW and MPS.
o Start the MPS and verify the operation of the voltage control and inch switches
on the LN-10. The inch controls should operate and the voltage readout should
display the open circuit voltage.
o Turn off MPS
 Closed Circuit Test
o Make all electrical connections between the AVW and MPS.
o Attach the weld lead that connects to the weld heat to ground.
o Start the MPS and verify the operation of the wire feed speed knob on the LN-10.
The wire feed speed should vary correctly and the meter relay (black line)
operation should correspond to the wire feed speed control.
o Turn off MPS
13. Remove zip ties/other strapping material

14. Hook off to the main lifting eye and begin to raise load, detach main mast shipping
brace, and remove the upper end bogie (The shipping wheel systems are heavy, watch
line of fire and pinch points)
Main Mast
Shipping Brace
Cable Tray
Shipping
Bracket
Upper End
Bogie
15. Lift AVW vertical, remove lower end bogie, and install compression arm platform
Second Cable
Tray Shipping
Bracket
Lower End
Bogie
16. Carefully stow all shipping components in the shipping container and retract rails
Loading
1. Remove AVW and MPS from shell (have the operator platform lowered)
2. Remove water pump from MPS (if Shipping Container is equipped with a mounting
position)
Water Pump Mounted in

Shipping Container
Additional Tube for Water

Pump Mounting
3. Open shipping container and extend rails until YELLOW paint just shows, adjust feet,
and crib as necessary
4. With the AVW held vertical, remove compression arm platform, install lower end bogie
and lock wheels
Cable Tray
Shipping Bracket
Lower End
Bogie
5. Place AVW on rails with the operator platform facing the shipping container
6. Lower the AVW, install upper end bogie on the compression arm so that it will not hit any
components and attach main mast shipping brace
Second Cable
Tray Shipping Main Mast
Bracket Shipping Brace
7. Replace horizontal drive motor turnbuckle with shipping brace (AVW 301) or remove and
stow horizontal drive motor (AVW 300)
8. Tie the cable tray to the ladder and/or mast (the tie points need to be no more than 2 - 3
feet apart to minimize risk of breaking the tray during shipment), or attach cable tray
shipping braces if supplied.
9. Collapse life line post

10. Unlock wheels and push the AVW completely into the shipping container
11. Install wheel locks and strap the AVW into the shipping container with provided ratchet
straps
12. Install water pump (if applicable), load compression arm platform and any lose cables
and hoses, and collapse rails. (see next page)
AVW Setup and Operation Page 1
Part 3 AVW Setup and Operation
3.1 2C300/301 Fall Prevention
1. Miller Durahoist Lifeline Post Setup

 See Figure 3 and 4.
 Install the Miller Durahoist Lifeline post on the anchor plate; insert the
anchor pin.
 Tighten the leveling screws to secure and level the post.
 Fully extend the post to the highest position (57.25”) as shown below.
2. Designed Tie off Anchors

 There are 4 approved tie off anchors on the 2C300/301 AVW: 3 rings on
the post and 1 ring integrated into the anchor plate.
 Tie off to the post rings (with post in high position) will allow personnel
access to all parts of the AVW and MPS.
 Operators must be tied off any time their feet are 4 in (100 mm) or more
above platform floors.
Figure 3: Lifeline Post Setup on 2C300 AVW
Lifeline Post Anchor Plate
Leveling Screws
Anchor Pin
Figure 4: Lifeline Post Setup
3.2 Interconnection diagram - 2C300/301 AVW to CBI 800 / 801D
1. See standard drawing 2C67-9 (old style) or 2C79-9 (new style) for MPS Electrical/Air hookup
instructions (see Appendix F, Section 1.
2. See standard drawing 2C300/301-40 for AVW master hookup instructions.
3. See Table 4 for Power Supply Setting for CBI 800 / 801D
4. The water pump and stand alone compressor mount in the MPS as in Figure 5.
Welding Power Supply Settings

CBI 801D (AVW MPS)
Output Contactor Switch Remote
A/V Switch Remote
Range Selector Switch High Output
CBI800D (AVW MPS)

Output Contactor Switch Remote
A/V Switch Remote
Table 4
Figure 5: Water Pump and Compressor

Front view Rear view
3.3 Welding Nozzle and Shoe Adjustments

Wire In/Out
Weld Shoe
Adjustment Slide
Adjustment for Seating

Shoe to Both Sides of
Vertical Joint Wire Center
Horizontal
Adjustment Slide
Air Balance Valve Push

Button for Engaging Horizontal Shoe
Shoe to Joint Adjustment Slide
Shoe Angle
Alignment Slide
Figure 6: Shoe Adjustments
3.4 AVW Control Settings
1. LN-10 Wire feeder (Figure 7 on next page)

(See contract specific WPS for additional parameter information)
Gas Purge
Cold Feed - Reverse
Cold Feed - Forward Voltage Indicator
Wire Feed Speed Indicator

Procedure
Trigger
Voltage Control
Control
Wire Feed Speed Control
Timer
Figure 7: LN-10 Control Panel Layout
 Trigger Mode Selection: Press the Trigger key to select “2-STEP STD” for normal
operation.
 Timer Selections: The Timer select key enables the operator to choose burn back, spot,
or gas timers. Press the timer key to select the appropriate function (preflow, spot, burn
back, or post flow), and use the Voltage Control to set the timers as shown below in
Table 5:
Timer Setting
Preflow 1.0 seconds
Spot 0.0 seconds
Burn back 0.2 seconds
Post flow 1.0 seconds
Table 5
 Control Selections: The Control select key enables the operator to

choose Run-In parameters. When the Control key is pressed, and the
“Run-In Volts/WFS” light is on, the settings of Run-In wire feed speed and
voltage are displayed. These values are set to optimize arc starting.
The Run-In Volts are set on a scale of 0.00 to 10.00. The appropriate
values are determined by the wire diameter and the total power
generated by the power source, and should be set as given below.
 Acceleration Selection: The wire feed acceleration of the LN-10 can be

set to 5 levels: 1 to 5. 1 is the slowest acceleration and 5 is the fastest.
To change the acceleration, hold the Gas Purge key closed, and then
press the Control key. The voltage indicator shows “Acc”; the
acceleration setting, 1 to 5, is shown in the wire feed speed indicator
display. Use the wire feed speed knob to change setting from 1 through
5.
Power Source / Wire Diameter

Lincoln DC1000 Miller 800
Parameter 1/16” 3/32” 1/16” 3/32”
Run-In Volts 3.0 3.5 3.8 3.8
Run-In WFS 350 300 350 300
Acceleration 1 1 1 1
Table 6
 Set wire feed speed on LN-10 control panel as required by WPS.
Red Line
Black Line
Redline amperage
control knob
Figure 8: AVW Main Control Panel
Horizontal Travel Vertical Travel
Figure 9: AVW Motor Controls

2. Base Speed Setting:
The base speed is set using the Baldor vertical travel motor control (Figure
9). Set the redline to 500 amps (Figure 8). Turn the vertical travel motor
control direction switch to “UP” and turn the vertical travel control to “ON.”
Adjust the travel speed POT so the travel speed indicator on the AVW Main
Control Panel displays 3 ipm. Make sure the base speed is set as required
by the WPS.
3. Stepping Speed Setting:

The stepping speed is set using the AVW Main Control Panel (Figure 8). Set
the redline to 0 amps. Turn the vertical travel motor control direction switch
to “UP” and turn the vertical travel control to “ON.” Adjust the stepping speed
POT on the AVW Main Control Panel so the travel speed indicator displays
12 ipm. Make sure the stepping speed is set as required by the WPS.
4. Switch Positions Prior to Start:
Horizontal Travel Control

Power Off
Travel Off
Vertical Travel Control
Power On
Travel Up
Run / Stop Run
AVW Main Control Panel
Travel Off
Water Pump On
Contractor Off
Table 7
3.5 Travel Control Explanation
The actual welding rate is controlled by means of a contact-less meter relay

mounted on the AVW control panel. This meter relay operates as a switch
between a “Base Speed” and a “Stepping Speed”. The “Base Speed” is
approximately 3 inches per minute (IPM), or 76.2 mm/min, of vertical travel set
on the Baldor vertical travel motor control. The “Stepping Speed” is
approximately 12 IPM (305 mm/ min) of vertical travel set on the AVW Main
Control Panel.
Contactless
Meter Relay
Redline
adjustment
knob
Base Speed
Adjustment
Stepping
Speed
Adjustment
Vertical Travel Control Main Control Panel
Figure 10
When a weld is started, the puddle height is no more than 1” (25.4mm) below the
top of the shoe. The puddle will progress upwards, and will continue to rise even
when the vertical travel is turned on (the AVW is in “Base Speed”). As the puddle
rises and the stickout decreases, the amperage reading on the meter relay,
displayed by the black needle, will increase. When the puddle reaches a level of
1/2” (12.7 mm) below the top of the shoe, the stickout will be 2” (50.8 mm), and
the amperage reading (the black needle) on the meter relay will be at the red line
setting. At this point the meter relay will switch the vertical travel from “Base
Speed” to “Stepping Speed” and the vertical travel will be greater than the
welding rate. This will cause the puddle to drop down, the stickout to increase,
and the amperage reading will decrease to below the red line. The meter relay
will switch back into “Base Speed” to allow the puddle to rise back up to 1/2”
(12.7 mm) below the top of the shoe.
The cycle repeats itself every few seconds and is sensitive within 20 amps,
providing precision control of the puddle and smooth vertical travel. Adjusting the
„red line‟ will adjust the puddle height during welding. Raising the „red line‟ will
raise the puddle height, and lowering the „red line‟ will lower the puddle height. A
small movement of the „red line‟ knob will make a noticeable change.
Figure 11
Note: The meter relay is light sensitive. If the control stays in “Base Speed” when
operating, then too much light is impinging on the meter. A sun shade should be
installed to restore normal operation.
3.6 Shoe Selection and Care
It is very important that the shoe be selected for the weld joint being used. See the
operating table (Table 8) and Figure 12 for proper shoe selection.
Figure 12
The width of the shoe must be no greater than 1/8” (3.2mm) wider than either side of
this joint, and no less than 1/16” (1.6mm) wider than either side of the joint
Shoes should never be smoothed using a grinder. Almost any depression or groove
will cause the weld surface to be rough. Even small indentations caused by using a
slag hammer to clean the shoe groove will be troublesome. A small half round file or
small 1” dia or 1 ½” dia. Drum sander or flapper wheel is the best tool for removing
rough spots. A wire brush (NOT a power brush!) can be used for fine polishing.
The following table shows the operating parameters for AVW electro gas multi –
pass / single vee welding with Lincoln NR-431 – 3/32 dia. Self – shielding flux cored
wire.
Shoe groove width should be 1/16” (1.6mm) – 1/8” (2.5mm) larger (each side) than
joint width. Wire stickout should be maintained at 2” (50.8mm)
3.7 Allowable Incline of Vertical Welds
Figure 13
3.8 Single Pass / Single Vee Welding
These charts should be used as a guideline for selecting proper shoes and welding
parameters. Good judgment should be used at the transition areas on these charts
for proper shoe size and control settings; manufacturing and fit-up must also be
taken into consideration.
Preheating the start of vertical joints is required for all AVW welds. See “WPS” for
required amount.
THE CONTRACT WELDING PROCEDURE MUST BE FOLLOWED TO THE

LETTER AND WILL SUPERCEDE THESE GUIDELINES.
The following table shows the operating parameters for AVW electro gas multi-
pass/single vee welding with Lincoln NR-431- 3/32 dia. Self shielding flux cored wire.
Shoe groove width should be 1/16” (1.6mm) – 1/8” (2.5mm) larger (each side) than
joint width. Wire stickout should be maintained at 2” (50.8mm)
These charts should be used as a guideline for selecting proper shoes and welding
parameters. Good judgment should be used at the transition areas on these charts
for proper shoe size and control settings; manufacturing and fit-up must also be
taken into consideration.
Preheating the start of vertical joints is required for all AVW welds. See the “WPS”
for the required amount.
THE CONTRACT WELDING PROCEDURE MUST BE FOLLOWED AND WILL

SUPERCEDE THESE GUIDELINES.
Single Pass / Single Vee Welding

Joint Detail Plate Back- Front Ammeter Voltage Wire Base Stepping
Thickness Up Bar Shoe Redline Feed Speed Speed
in. (mm) Speed IPM IPM
(mm/min) (mm/min)
3/8 (9.5) – 9/16 A 500 34 300 3 (76.2) 12 (305)
7/16 (11) 9/16 B 500 36 300 3 (76.2) 12 (305)
1/2 (13) 9/16 A 500 38 300 3 (76.2) 12 (305)

9/16 (14) 9/16 B 500 38 300 3 (76.2) 12 (305)
5/8 (16) 9/16 B 500 40 300 3 (76.2) 12 (305)
11/16 (18) 9/16 C 500 42 380 3 (76.2) 12 (305)

3/4 (19) 9/16 C or D 500 44 380 3 (76.2) 12 (305)
13/16 (21) 9/16 D 500 44 380 3 (76.2) 12 (305)
7/8 (22) 3/4 E 500 45 380 3 (76.2) 12 (305)
15/16 (24) 3/4 E 620 45 450 3 (76.2) 12 (305)

1 (25) 3/4 E or F 620 46 450 3 (76.2) 12 (305)
1-1/16 (26) 3/4 E 620 47 450 3 (76.2) 12 (305)

1-1/8 (29) 3/4 E or F 620 47 450 3 (76.2) 12 (305)
Note: A Wire Feed Speed of 300 is equal to a Drive Roll Speed of 58 RPM
A Wire Feed Speed of 380 is equal to a Drive Roll Speed of 75 RPM
A Wire Feed Speed of 450 is equal to a Drive Roll Speed of 89 RPM
Table 8
3.9 Set-up and Adjustments
1. Position the T-frame and AVW to the vertical joint. Install the remaining
rear back up bar.
2. Align the T-frame to the shell. See Figures 14 & 15.
3. Pull the T-frame idler wheel toward the operator so the rear flange of
each wheel is against the inside of the shell wall.
4. Confirm the water reservoir is full, the control switch is set to “Local”, the
bypass valve is slightly open, and the feed and return lines are attached
to the corresponding hoses on the AVW (Figure 16). Turn on the water
pump at the AVW Main Control Panel (Figure 8 and 10). Confirm pump is
operating.
Note: Do not use antifreeze unless required due to low ambient temperature. If
antifreeze must be used, only use enough to prevent freezing. Antifreeze reduced the
capability of the system to remove heat.
5. Verify the air compressor is on if a stand-alone unit is used.
6. Check all electrical connections. Check the shoe size and condition.
Change the contact tip if needed.
7. Engage the front shoe (Figure 6). Adjust the welding nozzle to achieve
the proper stick out and angle as required in the WPS (Figure11).
8. Retract the shoe from the shell and travel to the bottom of the joint.
9. Confirm the vertical post is the same dimension from the shell at the top
and at the bottom (Figure 14).
10. Confirm the vertical post is close to parallel the vertical joint
(Figure 15)
CHECK
DIMENSION
CHECK
DIMENSION
Figure 14
Figure 15
Bypass Line
Bypass
Valve
Fluid Return Fluid Feed Fill Level
Figure 16: Koolant Koolers water pump/cooler
Weld Head
Feed
Weld head
bracket Return
Shoe
Figure 17: Weld head adjustment bracket
11. Make and install the starting plug.
No welding required. Insert 1 ½” (38mm)

Backing: long piece of Siltemp tape into gap; fold
Copper bar over to seal gap and land area.
or ceramic
tape Note: Sandtex tape may be used in place
of Siltemp tape.
Siltemp D = 14” (36mm) for first ring and 4 ½”

tape (11mm) for all other rings
D
To bottom of
plate
Wrap a length of Siltemp tape around the

Siltemp tape top of a full electrode or stub (depending
“Hat” on ring to be welded) to form a plug large
enough to fill the joint to be welded. Insert
tightly into joint and tape to hold in place.
Cut a small piece of Siltemp tape and
place on top of the plug like a “hat”.
D = 14” (36mm) for first ring and 4 ½”

(11mm) for all other rings
Electrode
stub
Fig. 3-1
View of the plug and steel wool

without copper shoe
Plug with Copper

“Hat” shoe
Steel Wool
Roll steel wool ball approximately 1” (25mm) in diameter. Insert into joint on top of plug and
compact tightly. If rings are flush on the side to be welded and the shoe will fit tight, the
starting plug may be put at the base of the vert without the electrode stand off.
Fig. 3-2
12. Try to keep the horizontal slide (Figure 6) approximately centered.
13. Engage the shoe to the shell and make sure there is ¾” to 1” (19 to
25mm) of slide travel remaining.
14. Adjust the shoe so it is seated on either side of the joint tightly and
centered. See Figures 11 and 12.
15. Check the underside of the sure to be sure it is centered.
16. Check the weld head to see if it is perpendicular to the joint (Figure 17).
17. Verify stickout length and wire angle per Figure 11 or WPS if different.
18. Check the shoe to joint tracking up the vert. Confirm the shoe remains
seated on both sides.
19. Preheat the start of the vertical joint as required by WPS.
20. With the shoe correctly engaged, travel up slowly to make sure the shoe
is properly seated. Stop when the shoe is 1” to 1 ¼” above the plug.
21. Insert steel wool into the joint on top of the starting plug
(See Table 9b).
22. Inch the wire down and adjust so the wire arc strike is centered in the
joint. Do not allow the wire to touch the steel wool. Leave at least ¼”
(6mm) gap between the end of the wire and the steel wool.
3.10 Welding Start Sequence
1. Make sure the horizontal travel switch is “OFF”.

2. Turn the vertical travel switch “ON” and the direction is UP (forward).
3. Turn Contactor switch “ON”
4. Welding starts, puddle is established and builds up (this happens within
a couple seconds)
5. Turn travel switch “ON” on AVW Main Control Panel when the puddle
comes up to 1/2" below the top of the front shoe. (AVW is now in
automatic travel)
6. Adjust redline to maintain proper puddle height (1/2” below top of shoe)
7. Check and adjust the voltage
8. Start four point check cycle to ensure quality weld (Figure 17)
3.11 Welding Stop Sequence
1. Turn contactor switch “OFF”

2. Turn travel switch “OFF” when puddle solidifies
3. Retract shoe
Figure 18: 4 – Point Check System
3.12 Conversions and Options
See the local weld manager for use and additional information on these conversions options.
1. EGW to FCAW With Oscillation Conversion
Open drawing from CMS for printable copy and latest revision. 2C301-30
2. AVW EGW Oscillator Conversion; Low Temperature Service

3. AVW 301 to AVW 301-Long Conversion Instructions

Width 83” (2108mm)
Height 255” (6400mm)
Weight 2910 lbs (1320kg)
a. To do at the warehouse
 Disconnect all hoses and cables (both ends) that go through the cable carrier,
2C301-7-A.
 Remove the cable carrier from the AVW and strip out all hoses and cables.
 Move the vertical slide, 2C301-19-A, towards the top of the post and secure it to
the post so that it will not move.
 Disconnect the lower end of the chain, 2C301-29-3, where it connects to the
chain adaptor (29-7 & 8) at the left side equipment bracket, 2C301-10-A.
 Remove the lower wheel mounting assembly, 2C301-26-A.
 Alter the bottom of the post, 2C301-29-1, per detail “C” on drawing 2C301-185.
 Add the new section of roller chain, 2C301-186-1 and the connecting link 2C301-
186-2 per drawing 2C301-186. Install the new post extension 2C301-185-A
 Check for excessive mismatch between the post extension and the old post.
Verify that the vertical slide will pass across the splice without binding
 Reinstall the Lower Wheel Assembly 2C301-26-A and make roller chain
connection to the chain adaptor (29-7 & 8) at the left side equipment bracket,
2C301-10-A.
 Add the new, additional cable carrier section, 2C301-184-11, to the cable carrier,
2C301-7-A, per drawing 2C301-184
 Remove existing weld head components - The 2C301-61-A, Compression
Cylinder Mounting and slide Assembly, and the 2C301-125-A Shoe Holding
Swivel.
 Install the FCAW conversion kit, 2C301-30-A, per drawing 2C301-181 using
adaptor plate 2C301-181-1
 Make sure that the jumper between B3 and B4 is as described in detail “A” on
drawing 2C301-30.
 Install the new, longer hoses and cables shown on drawings 2C301-188, 2C301-
189, and 2C301-190, in the altered cable carrier.
 Attach the altered cable carrier and make all cable and hose connections.
b. Warehouse prep for shipping
 Disconnect the roller chain at the bottom of 2C301-10-A and remove the lower
post extension.
 Remove the lower wheel mounting assembly form the lower post extension.
 Reattach the lower wheel mounting assembly to the bottom of the existing
altered post section, 2C301-29-1 (See drawing 2C301-185) and install all
shipping "Gadgets" and Bogies as you would for shipping an existing AVW 301.
(See drawing 2C301-130)
 Store the AVW in the shipping container per instructions (see Appendix H Load,
3-11)
 Strap down (somewhere in the container) the 2C301-185-A post extension
(Attach the 3 splice plates with its bolts to keep it all together)
 Do not ship a water pump assembly, 2C301-41-A, with the AVW 301-Long
c. Field assembly
 Unload the AVW from the shipping container per instructions (see section 2.4,
Unload 1-6)
 Remove the lower wheel mounting assembly, 2C301-26-A from the shipped
AVW 301.
 Attach the 2C301-185-A post extension to the AVW 301 per the Warehouse
Instructions above.
 Reattach the lower wheel mounting assembly to the post extension, 2C301-185-
A
 Reconnect the roller chain per the Warehouse Instructions above.
 Verify all hose and cable connections per drawing 2C301-187.
d. Field prep for shipping
 Reverse items 5 through 1 in “Field assembly” above.

 Perform items 1, 2, 3, and 5 in “Warehouse prep for shipping” above.
3.13 Front Shoe Sizes
Plate Bevel Gap Land Joint Min Max Shoe

Thickness Angle Width Shoe Shoe Size
Width Width
0.375 60 0.3125 0.125 0.601 0.726 0.851 A
0.4375 60 0.3125 0.125 0.673 0.798 0.923 B
0.5 60 0.15625 0.125 0.589 0.714 0.839 A
0.5625 60 0.15625 0.125 0.658 0.783 0.908 B
0.625 60 0.15625 0.125 0.734 0.859 0.984 B
0.6875 60 0.15625 0.125 0.806 0.931 1.056 C
0.75 60 0.15625 0.125 0.878 1.003 1.128 C or D
0.8125 60 0.15625 0.125 0.95 1.075 1.2 D
0.875 60 0.15625 0.125 1.022 1.147 1.272 E
0.9375 55 0.15625 0.125 1.002 1.127 1.252 E
1 55 0.15625 0.125 1.067 1.192 1.317 E or F
1.0625 50 0.15625 0.125 1.031 1.156 1.281 E
1.125 50 0.15625 0.125 1.089 1.214 1.339 E or F
Note: Shoe width is based on joint width + 0.125 to 0.250
Table 3-1
Troubleshooting Page 1
Part 4 Troubleshooting
4.1 Trouble Shooting Weld Quality
Throughout the welding cycle, the operator‟s attention should be devoted to the
assurance of a high integrity weld. This can be achieved simply by following the
four point check cycle in Figure 17. (Become familiar with the weld defects and
their causes in this manual).
Refer to the contract quality control documents for allowable discontinuities.
1. Porosity - Starting
 Incorrect Control settings – Low wire feed speed and/or high voltage.
 Excess moisture, either from condensation or rain, dew, etc. Preheating
at the start of an AVW weld is required per WPS. Starting plug material
will pick-up moisture and should be stored in a dry place.
 Improper electrode location causing arc either to the join side or copper
shoe. This will cause the rapid travel cycle to commence too soon.
 Long arcing for any reason
2. Porosity – In the weld

 Puddle too close to the top of the shoe. This can be the result of an
improper control setting, (puddle height) or the shoe to the tip spacing
may be too much so that with the proper stick-out the puddle is too high.
 Lack of proper weather protection in high wind conditions.
 Contaminated electrode.
 Electrode feeding too slow due to dirty or worn curved nozzle.
 Shavings in power block where curved nozzle is connected.
 High-voltage – Too much stick-out will cause high voltage, also many
meters are incorrect and should be checked by using a good voltmeter.
 Low Wire Feed Speed – The volt setting may be correct but if the wire
feed speed is slower than required for that setting the effect will be the
same as high voltage.
 Short electrical stick-out.
3. Other Weld Discontinuities
Weld Centerline Cracking (a-c)
Deep narrow arc gouging – hand pass may

a be needed to balance the width to depth
ratio
Excessive penetration – generally caused

by the arc location being too close to the
root of the joint or too much angle on the
b
wire
Excessive wire feed speed – this is

indicated by a narrow appearance to the
weld and usually traps slag along the
edges. There are times due to the size of
c
the joint when the recommended wire feed
speed is excessive and should be reduced
Lack of Fusion to Both Edges (c)
Excessive wire feed speed or electrode

arcing to the root or sides causing the
d machine to travel rapidly.
Table 4-1
Cold Lap
Wire angled into the joint too much.
Shoe groove too large for welding rate

– reduce wire feed speed.
Lack of Sidewall Fusion
Electrode or arc off center. Check shoe

location first as it can work to one side
so the groove is no longer centered on
the joint.
Surface Roughness
Arc too close to the shoe.

Check wire for excess curve back
toward the shoe. Puddle to low causing
arc to play on shoe.
Shoe groove condition. Any surface

erosion or roughness in the area just
below the puddle level will cause
dragging of the molten metal
Under Fill
Shoe groove to narrow.
Wire feed speed to slow. This causes

low deposition rate and allows too
much melting of the plate edges
High voltage.
Table 4-2
4.2 Troubleshooting AVW Control
Before attempting any repairs on the AVW control, make sure that you have the
correct wiring diagrams and schematic diagram. The CB&I Standard drawing
numbers 2C300-39 and 2C301-39 show the wiring for the Vert Welder.
The numbers located on the wires correspond to the numbers used on the drawings.
This allows easy checking of the wiring. Before attempting to use the troubleshooting
guide, know where your problem is located. The following is a simple check that can
be performed on the control in order to isolate the problem.
Proper incoming power must be supplied and maintained to this system throughout
its use.
Minimum incoming power supplied at the AVW control panel: 110 VAC
1. Is the water pump running and is water flowing through the shoe and
valve?
2. Wire feeder check
 Remove the wire from the feed rolls
 Turn the wire feed speed control to 0
 Place the wire feed switch in the forward position
3. To check the welding machine controls:
 Place the wire feed switch in the neutral (center) position. Turn the weld
contactor switch on. The volt meter should indicate the open circuit
voltage of the welding machine.
4. To check out the vertical travel control:
 Turn the AVW control panel on with all other switches in the off or
neutral positions. Adjust the stepping speed control to read 8 on the dial
face (located inside the AVW control panel). Set the red line to 500
amps.
 Turn the ATF vertical control panel off with the vertical travel direction
switch in the up position and the travel speed adjustment knob set to 2
on the dial face.
 Turn the AVW travel switch to the on position. The carriage should start
moving slowly upward. While moving, turn the red line to 0; vertical
travel should increase in speed.
 Turn the red line back up to 500. Vertical travel should decrease in
speed.
 If the above tests were successful and all controls performed as
described, the problems with the unit may be due to operating
procedures. Check Section 2 of this manual to verify correct setup of
this piece of equipment.
4.3 Troubleshooting T-Frame
1. Before attempting any repairs on this control, make sure that you have the correct wiring
diagrams and drawings. The following CBI Standard drawing numbers can be used to
troubleshoot components attached to the T-Frame: Travel controls; 2C301-58, Vertical travel;
2C301-29, Vertical limit switch; 2C301-45, Horizontal travel; 2C301-113, and general wiring and
hook up diagrams 2C301-39 and 2C301-40 respectively.
2. Prior to replacing drive controls or motors check the cables, cable connections, and
jumper/wire connections in the control units.
If for some reason the controls do not operate as described above then refer to the
troubleshooting guide below.
4.4 General Troubleshooting Guide
Welding Controls
Problem Cause Correction
Welding machine contactor Incorrect wiring of Check wiring of machine.
does not work machine, broken control, Check control cable.
coolant pump not on, flow Check for plugged orifice,
switch not working, bad kinked hose, or water
control relay connection level. Check quick
disconnects, pump, flow
switch, and control relay
for correct operation
No remote control of Incorrect setting of
machine. machine, broken control, Check control cable and
broken control cable. switches on machine.
Table 4-3
Automatic Vertical Travel Control

Travel control will not Improper Welding Check operating
switch into high speed Parameters, defective procedure, check for
meter relay, incorrect proper operation of meter
wiring of meter relay relay, and check wiring in
circuit, direct sunlight on meter relay circuit.
meter relay. Shade meter relay form
direct sunlight.
Travel operating in high Defective control cable, Check control cable,
speed only control board, or speed replace control board. Arc
rheostat; improper wiring too close to plate or shoe
of vertical travel circuit, will also cause high speed
defective meter relay or operation.
loose or broken wire.
Table 4-4
Water Pump
Pump gear shaft gummed Remove flange, clean and
Hard to start, blows up lubricate shafts (Use
breaker, does not start silicone containing light
oil).
Motor to pump coupling
Motor runs, pump doesn't loose Tighten set screws
Water gets too hot Not enough water, pump Add water, run pump
not running enough, continuously, do not use
permanent antifreeze in permanent antifreeze, do
tank not use any more
antifreeze of any type than
absolutely necessary.
Table 4-5
Supplies Page 1
Part 5 Supplies
5.1 Recommended Electrical Spare Parts
Quantity Description
1 Baldor BC154 speed control with
FWD/REV/BRK switch, ON/OFF switch and
CBI installed multi turn Potentiometer
1 Bourns Part #3540S-1-502 10-turn
Potentiometer (5 K Ohm)
1 Proteus Flow Switch
1 Allen –Bradley control switch Part #800T-
H2B
1 Simpson Contactless Meter Relay, Single
Set Point, Model 3323XA Cat. No. 21437 ,
0-50 AMP Scale, 0-500 AMP DC Scale 
OR Beede Meter Relay Part #BE/MR4-13-
07/0-50MVDC, scale 0-800 DC Amperes
6 Armature fuse for BC154 drive control, 8
Amp., 250 Volt, fast acting type ABC-8
6 Armature, fuse for BC154 drive control, 12
amp, 250 volt, fast acting type ABC-12
1 Flow Switch, Proteus 100b110
1 Lincoln LN-10 feeder control Part #K1562-2
1 LN-10 wire drive assembly Part #KK1563-3
1 Veeder-Root rate-meter Part #C628-40000
Table 5-1
Supplies Page 2
Recommended Mechanical Spare Parts
Quantity Description CBI Piece No

1/vert + 12 Contact Tips 3/32” (Lincoln T-13000 3/32”) 2C16-10-3
2 Bent Nozzle (Lincoln K-176 3/32”) 2C300-2-1
4 Hansen Connector Plug B2K-16 2C16-10-13
4 Hanson Connector Socket B2H-16 2C16-20-10
4 45 Degree Street Elbow ¼” to ¼” NPT Galvanized 2C16-20-2
4 ¼” NPT Hex Pipe Nipple Brass 2C16-20-3
2 Wire Guide Tube 2C300-2-4
6 Hose Clamps Adjustable ½” – 1 ½”
Moving Copper (Front) Shoes
6 Copper Shoe Size, “A” 2C16-7-7A
6 Copper Shoe Size, “B” 2C16-7-7B
6 Copper Shoe Size, “C” 2C16-7-7C
6 Copper Shoe Size, “D” 2C16-7-7D
6 Copper Shoe Size, “E” 2C16-7-7E
Shoe sizes supplied to be determined by contract
Back-up Copper Shoe – For Single Bevel Verts
10 ¾” – 9/16” Grooved Dry Shoe, 30” Length 2C16-8-1
2 ¾” – 9/16” Grooved Dry Shoe, 15” Length
2 Back-up Bar Aluminum 2” x 3/8” x 10‟
Table 5-2
5.2 Recommended Hand Tool List
1 Screwdriver (small) 1/8” Blade x 4-3/8” Length
1 Screwdriver (medium ¼” Blade x 8 ½” Length
1 Adjustable Wrench, 6”
1 Adjustable Wrench, 10”
1 Wire Cutters Diagonal Heavy-Duty 8” Length
1 Pliers Slip-Joint 6” Length
1 Hex Key Set-9 Key, 5/64”, 3/32”, 7/64”, 1/8”. 9/64”, 5/32”, 3/16”, 7/32”. ¼”
1 Level Torpedo Aluminum Magnetic 9” Length
1 Ball Peen Hammer 8 ounce Head 13” Length
1 Tape Measure 8‟
1 Cold Chisel Standard 5/16” Cut x 4 ½” Length
1 6” C-Clamp
1 Slag Hammer
1 Scratch Brush
1 Flashlight
1 Black & Decker Die Grinder #12-1/2” Collet
Table 5-3
Supplies Page 3
5.3 Miscellaneous Supplies List
2 Rolls Fiberglass Heat Resistance Tape 3M P/N 3655 MCT 3608924

1Ft/Vert Sil-Temp Heat Barrier Woven Cloth Tape Wt 65 -1 ½” wide
4 Packs Steel Wool
20 Phenolic Slag Sticks ½” x ½” x 8” length
2 cans High Pressure Moly Lubricant Osborn #76209
5 feet Emery cloth Strip 2” wide
1 Roll Teflon Pipe Tape
10 Emory Flapper Wheel 2” dia. X ¾” Wide x ¼” Shaft
Ft of verts Ceramic Triangle Back-up Tape 3M P/N SJ8073-60 if specified by
contract
Table 5-4
AVW – 300/301 Manual Part Appx A
Appendix A - Forms Page 1
Appendix A – Forms
Checklists
AVW Checklist Outbound CMS-830-17-FM-40002

AVW Checklist Inbound CMS-830-17-FM-40003
Inspection Test Plans
Field ITP CMS-830-17-FM-40004

AVW 301- Fabrication ITP
AVW 301- Fabrication ITP Reference Drawing
AVW 301 Long - Fabrication ITP
AVW Check Out List
(Outbound)
Equipment Inspection Checklist
MODEL: SERIAL NUMBER: DATE:

Checked By: Work order # Date:
Warehouse Manager or Designee
Items to Inspect Reference Drawings Repair Repaired or Comments

AVW-301 Needed Acceptable
1.0 Structural / Mechanical
1.1 Mast
Check straightness with stringline; must be +/-
2C301-29
1.1.1 3/16"
Inspect for arc stricks, dings, cus, and othere
2C301-29
1.1.2 damage; reapir as required
Inspect cam follower contact surface for galling,
wear or excessive corrosion. Grind or buff as
2C301-19
required and coat with a thin layer of
1.1.3 deoxaluminite paint.
1.1.4 Inspect top and bottom caps for damage. Assure 2C301-26 / 80
Inspect lift lug. Check for straightness, inspect
welds, check hole for cracks and wear, and assure
2C301-29
stiffener is installed per latest revision of drawing
1.1.5 2C301-29.
Inspect lower horizontal guide wheel assumbly for
proper function of pivot, turnbukle, wheel, and 2C301-26
1.1.6 brake.
1.2 Headframe and Back Yoke
1.2.1 2C301-29
damage; reapir as required.
1.2.2 Inspect wheel and yoke hinge assembly welds. 2C301-115
1.2.3 Inspect Miller fall protection mount welds. 2C301-24
1.2.4 Inspect jack lugs for bending and hole wear. 2C301-96 / 97
Assure drive and idler hnge pins are functional and
1.2.5 2C301-24
cotter pins are in place.
Assure wheel carriage turnbuckles are per drawing
1.2.6 2C301-85 / 113
and installed correctly.
Assure mast clamping bolts are the correct type,
1.2.7 2C301-98
size, installed correctly, and tightened.
Form Number: CMS-830-17-FM-40002 Issued for Use: 27 Jan 2010 Page 1 of 9

Assure the mast to yoke clampng and adjusting
1.2.8 bolts are the correct type, size, installed correctly, 2C301-97
and tightened.
Assure the horizontal guide wheels are properly
1.2.9 2C301-96
installed and in good working order.
1.3 Ladders
Inspect ladders and extensions for damage; repair
1.3.1
as required.
Assure bolts are the correct type, size, installed
1.3.2 2C301-89
correctly, and tightened.
Assure two (2) ladder extensions and ladder
1.3.3
stabilizers are included in shipment.
1.4 Operator's Platform
1.4.1 2C301-20
1.4.2 2C301-20 / 21 / 22
1.4.3 Clean, inspect, and lubricate all cam followers. 2C301-22
Inapect cam follower contact surface for galling,
1.4.4 wear. Grind or buff as required and coat with a 2C301-22
thin layer of deoxaluminite paint.
1.4.5 Verify free vertical travel of platform post. 2C301-20
1.4.6 Check froper tightening of platform travel stop. 2C301-21
1.5 Compression Arm Platform
1.5.1
1.5.2
correctly, and tightened. 2C301-123
Trial fit back platrorf to back yoke. Platform
1.5.3 should install and remove without need for
excessive forxe. Align as required.
Assure all retaining bolts are properly sized and
1.5.4 2C301-96
included with shipment.
1.6 Vertical Carriage
1.6.1
2C301-19 / 29
1.6.2

1.6.3 Inspect, clean, and lubricate all cam followers.
Disconnect the travel chain and manually move the
carriage through its entire range of travel. Adjust
2C301-19 / 29
1.6.4 cam followers as required so there is no excessive
force required throughout the entire range of
travel.
1.7 Control Pannel Mounts
1.7.1
1.7.2
correctly, and tightened. 2C301-54 / 55
Assure hinges have movement throughout their
1.7.3 entire range and are free of cracks and other
damage.
Assure the travel limit stops are functional and
1.7.4 prevent the control panesl form interfering with the 2C301-45
upward movement of the platform mast.
1.8 Cable Management System
Inspect the entire length of Kabelschlepp for
1.8.1
damaged or missing components.
1.8.2 2C301-7
Assure the top three (3) Kabelschlepp links can
1.8.3 bend both directions: toward and away form the
mast.
1.9 Jacking System
Inspect pump, hoses, check valve, and cylinder for
1.9.1
damage and leaks; repair as required.
2C301-9
1.9.2 Fill the system and bleed air.
1.9.3 Functinally test jack through entire stroke.
2.0 Operating Systems
2.1 Horizontal Travel
2.1.1 Clean and inspect drive and idler wheels. 2C301-122
Clean, inspect, and lubricate drive and idler wheel
2.1.2 2C301-113 / 85
bearings.
Clean, inspect, and lubricate drive chain. Install on
2.1.3
high speed dprokets. (large driving, small driven)
Inspect gearbox for leaks, replace gaskets as 2C301-113
2.1.4
required.
Assure gearbox vents are properly located and
2.1.5
clean.

2.1.6 Fill gearbox with synthetic lubricant.
Check drive motor coupling. Assure keys and set
2.1.7 screws are properly installed. Assure elastomer
insert is in good condition.
2.1.8 Inspect horizontal drive motor.
2.1.8.1 Assure motor is proper size and type.
Inspect brushes. Replace if brush length is less
2.1.8.2
than 3/8" or if brush is damaged or galzed. 2C301-113
2.1.8.3 Clean communicator if required.
Inspect drive cable pigtail. Assure insulation is
2.1.8.4 undamaged and cable is properly secured in the
cable gland.
Inspect dthe drive cable pigtail amphenol
connector. Check for broken wires, good solder
2.1.8.5
connections, proper insulation and installation of
connector body and strain relief.
2.1.9 Inspect horizontal drive cable.
2.1.9.1 Assure insulation is undamaged.
2.1.9.2 Assure proper routing in cable routing system.
2C301-72
Inspect amphenol connector. Check for broken
2.1.9.3 wires, good solder connections, proper insulation
and installation of connector body and strain relief.
2.1.10 Inspect horizontal travel control.
Check for proper installation of input power and
2.1.10.1
output drive cables.
2.1.10.2 Check for proper jumper settings.
2.1.10.3 Check for proper amature fuse.
Check and replace switches and switch boots as 2C301-58
2.1.10.4
required.
2.1.10.5 Check 10-turn potentiometer and counting dial.
Energize and functionally test system. (Note:
2.1.10.6 Forward travel should be to the welding operator's
right)
2.2 Vertical Travel
2.2.1 Clean, inspect, and lubricate drive chain. 2C301-80
Inspect travel chain end connections for proper
fabrication and wear or elongating of mounting
2.2.2 2C301-29
holes. Replace if there is any sign of wear or
elongation.
2.2.3 Clean, inspect, and lubricate upper travel bearings. 2C301-80

2.2.4 Clean and inspect lower sproket and bearing. 2C301-26
2.2.5 Inspect upper drive sproket and bearing. 2C301-80
2.2.6 Inspect drive coupling, chain, set screw, and key. 2C301-29
Inspect gearbox for leaks, replace gaskets as

2.2.7
required.
Assure gearbox vents are properly located and
2.2.8
clean.
2.2.9 Fill gearbox with synthetic lubricant.
2.2.10 Inspect vertical drive motor.
2.2.10.1 Assure motor is proper size and type.
2C301-80
Inspect brushes. Replace if brush length is less
2.2.10.2
than 3/8" or if brush is damaged or galzed.
2.2.10.3 Clean communicator if required.
Inspect drive cable pigtail. Assure insulation is
2.2.10.4 undamaged and cable is properly secured in the
cable gland.
2.2.10.5 Inspect drive cable pigtail amphenol connector.
2.2.11 Inspect vertical drive cable.
2.2.11.1 Assure insulation is undamaged.
2.2.11.2 Assure proper routing in cable routing system.
2C301-72
Inspect amphenol connector. Check for broken
2.2.11.3 wires, good solder connections, proper insulation
and installation of connector body and strain relief.
2.2.12 Inspect vertical drive control.
Check for proper installation of input power and
2.2.12.1
output drive cables.
2.2.12.2 Check for proper jumper settings.
2C301-58
2.2.12.3 Check for proper amature fuse.
Check and replace switches and switch boots as
2.2.12.4
required.
2.2.12.5 Check 10-turn potentiometer and counting dials.
Energize and functionally test system. (Note:
2.2.12.6
Forward travel should up)
Functionally test meter relay with vertical travel
control system. When the redline is below the
black line, the 10-turn potentiometer on the
vertical control should control the travel speed
2.2.12.7
(base speed). When the redline is above the black
line, the 10-turn potentiometer on the integrated
control panel should control the travel speed
(steping speed).
Test the vertical travel limit switch and override
2.2.12.8
switch.

2.3 Vertical Travel Speed Indicator System
2.3.1 Check installation and location of sensor gear. 2C301-80
2.3.2 Check proper type and connection of signal cable 2C301-72
Energize andoperate system, verify peoper travel

2.3.3 speed is indicated +/- 5%. Reprogram indicator if 2C301-35
required.
2.4 Weld Head and Slides
2.4.1 Clean, inspect and lubricate all slides. 2C301-126 / 61 / 62
2.4.2 Adjust slide "Gibbs" as required. 2C301-126
2.4.3
2.4.4 Check air system for leaks.
Check opeation of air slide. Repair or replace air
2.4.5 2C301-61 / 62
cylinder and/or valve as required.
Inspect welding torch, contace tip, wire conduit,
2.4.6 2C301-2
and conduit adaptors. Repair or replace as needed.
Clean, inspect, and lubricate shoe mounting set
2.4.7 2C301-125
screws.
2.5 Water Cooling System
Inspect water hoses for cracks, damage, proper
2.5.1 2C301-41 / 73
connections, and proper routing.
Inspect proteus flow switch for peroper
2.5.2 2C301-4
installation: Flow form A to B
Inspect Proteus flow switch cables (power in and
2.5.3 2C301-4
signal out).
Inspect water pump hoses for cracks, damage,
2.5.4 2C301-73
proper connections, and proper routing.
Check power supply cable to water pump for

2.5.5
damaged insulation, proper plug, and connection
Check water pump control cable from intergrated
2C301-41
2.5.6 control pannel to contactor box for damaged
insulation and proper connection.
Check water pump contactor, contacts, and
2.5.7
heaters.
Fill system with water, instal test shoe, and
2.5.8
energize.
2.5.8.1 Check all connections for leaks.
2.5.8.2 check for proper flow.

Check operation of Proteus flow switch by
checking continuity between pins A and C on the
LN-10 feeder drive connector (2C301-37-40).
Continuity should be persent when the contactor
2.5.8.3
switch is on and water is flowing. There should be
no continuity when the flow is restricted or
stopped, or the contactor swithc is in the off
postion.
2.6 Wire Feed System
Assure proper installation of feed rolls, wire guide
2.6.1 2C301-2 / 3 /13
blocks, wire straightener, and conduit adapter.
Check interconnection cable between wire feeder
2.6.2 control and wire feeder box. Inspect insulation and 2C301-40
amphenol connections.
Check control cable form wire feeder control to 24
2.6.3 VAC transformer, inspect insulation and ampnenol 2C301-69
connections.
Check control cable form 24 VAC transformer to
2.6.4 welding power source. Inspect insulation and 2C301-69
ampnenol connections.
Check cable form current sensing switch to wire
2.6.5 feeder control. Inspect insulation and ampnenol
connections.
Check settings of DIP switches inside wire feeder
2.6.6
control.
Connect welding power source, and assure contact
2.6.7
tip is clear of work piece.
Energize welding power source and test
2.6.8
functionality of the wire feed system. (VOC test)
2.6.8.1 Check inch up and down and gas purge functions.

Set function timers, acceleration and run-in
2.6.8.2
conditions per AVW manual.
With Water cooling system operating, turn the
contactor switch on. The feed rolls should operate
2.6.8.3
at run-in speed, and open circuit voltage (OCV)
from the welding source should be present
De-energize the power source and setup for short
2.6.9
circuit test.

Install a section of 4/0 welding cable from the
2.6.9.1
welding torch to the workpiece.
2.6.9.2 Energize the welding power source.
With the water cooling system operating, turn the
contactor on. The feed rolls should operate at
speeds controled by the wire feed speed knob on
2.6.9.3
the LN-10. The meter relay should measure
current and the current should be controllable by
the output control knob on the LN-10.
3.0 Safety Systems
3.1 Load Arrestor
Check lower shacle for proper type, size, wear,
3.1.1
and correct installation.
Check carriage attachment lug for straightness and
3.1.2
proper welding.
Inspect the entire length of load arrestor cable for
3.1.3
arc strikes, broken strands, kinks, or other damage. 2C301-124
3.1.4 Inspect load arrestor housing for damage. Assure
Inspect upper attachment bars for proper welding
3.1.5
and inspect holes for cracks or elongation.
Assure upper attachment bolts are the correct type, size,
3.1.6 installed correctly, and tightened.
3.2 Travel Limit Stops
Assure travel limit stops are in place and correct
3.2.1
per drawing 2C301-45.
Adjust upper limit switch stop as appropriate for
3.2.2 2C301-45
pole length.
Run the vertical travel carriage through its entire
3.2.3
tange and verify the limit stops are correctly

AVW Check Out List
(Inbound)
Equipment Inspection Checklist
MODEL: SERIAL NUMBER: DATE:

Checked By: Contract received from: Date:
Warehouse Manager or Designee
Items to Inspect Good Repair Repair Comments

Cond. Needed Comp.
1.0 Structural / Mechanical
1.2 Mast
1.2 Headframe and Back Yoke
1.3 Ladders
1.4 Operator's Platform
1.5 Compression Arm Platform
1.6 Vertical Carriage
1.7 Control Panel Mounts
1.8 Cable Management System
1.9 Jacking System
2.0 Operating Systems
2.1 Horizontal Travel
2.2 Vertical Travel
2.3 Weld Head and Slides
2.4 Control System
2.5 Water Cooling System
2.6 Wire feed System
3.0 Safety Systems
3.1 Load Arrestor
3.2 Travel Limit Stops
4.0 Shipping Container
4.1 Rails
4.2 Shipping Bogies
4.3 Shipping cross-member
4.4 Water Pump Mount
4.5 Other Shipping Equipment

AVW Field Inspection Form
Inspection Type: √ Type of Report: Monthly _____ Annual ______

A Daily - visual inspection, no written report required. Contract Number ___________________________
B Monthly - written report optional unless required.
Location __________________________________
(see note on page 2)
C Annual - written report required, use this form.
Date _____________________________________
AGW to receive this type of inspection also when:
1) New or altered
Serial Number _____________________________
2) Idle one to six months
3) Stand-by or idle over six months Inspection Frequency
Items to be Inspected: A B C
(“X” indicates frequency. Place " √" beside “X” indicating Daily Monthly Annual Conditions Noted
item has been inspected and is ok, place “P” beside “X” Visual Report Report
indicating a problem) Date Date
1.0 General
1.1 All chains, pins, wheels, and stops are in good working X X X
condition (check for broken links, excessive wear or
corrosion, kinks, and/or broken welds). Also grease wheels
as necessary.
1.2 All fire extinguishers are in good working condition. X X X
(check tags and inspection sheets)
1.3 Check for missing parts, excessive wear or any X X
modifications.
1.4 All un-necessary material/equipment has been removed X X X
from the work space.
1.5 All safe guards are in place, work correctly, and are not X X X
modified.
1.6 Inspection tag installed on panel. X X
1.7 Person performing the inspection must be trained by X X X
foreman on proper equipment usage instruction.
1.8 Operation and safety manual available on site. X X X
1.9 Lifting lug in good condition. X X
1.10 Check slide assemblies for ease of movement and X X
proper lubrication.
2.0 Platform
2.1 All decking in good working condition. X X
2.2 Hand-rails are in good working condition (check for X X
missing or damaged parts, broken welds, etc).
2.3 All ladders are in good working condition (check for X X
missing or damaged parts, broken welds, excessive
corrosion, and stability).
2.4 Tie-off device installed and in good working condition X X
(check for burn marks, excessive corrosion, missing or
damage parts).
2.5 All bolting on operator's platforms are in good condition X X
and secure.

AVW Field Inspection Form
Items to be Inspected: Inspection Frequency

(“X” indicates frequency. Place "√" beside “X” indicating A B C
item has been inspected and is ok, place “P” beside “X” Daily Monthly Annual Conditions Noted
indicating a problem) Visual Report Report
Date Date
3.0 Electrical
3.1 All electrical devices are in good working condition. X X
Check for correct operation of switches and other controls,
tight connections (power box, ground etc.), and controls are
in the off or neutral position.
3.2 All leads in good condition (check for worn, frayed, or X X
broken areas, as-well-as tight connections). Check
equipment for arc strikes.
3.3 Welding components such as the MPS are in good X X
working condition.
3.4 All limit switches are in place, work correctly, and are not X X
modified.
4.0 Drive System
4.1 All hoses, fittings, and motors are in good working X X
condition (check hoses for kinks or damage).
Notes:
Distribution:
Original - Foreman Inspector:
____________________________________
Copy - Equipment Coordinator Signature
Copy - Construction Supervisor
Copy - District Safety Supervisor Supervisor:
____________________________________
Signature
NOTE:
This form is supplied as a means to provide consistent inspection for this equipment by field or warehouse personnel.
Formal documentation is only required annually unless more frequent documentation is mandated by:
1. The laws of the responsible governmental jurisdiction in which the machine is being used or;
2. CB&I's customer or;
3. The CB&I business unit the equipment is being used by.
Annual inspection shall be documented and the form distributed as shown.

Document Id.: ITP-2C301
INSPECTION AND TEST PLAN DETAIL
Revision: 1
Project Name: 2C301 Fabrication Contract No.:
Controlling Document Inspection Involvement

Activity Resp. Acceptance
Activity Description CB&I Third Remarks
No. Party Criteria CB&I Client
Spec. Proc. Dwg. QC Party
Visually Inspect welds attaching 2C301-19-1

1 piece 121-2 to 121-1. Front view VI4
2 Visually inspect all welds VI4

Check material & length of piece
3 14
Visually inspect aluminum welds
attaching toe boards to floor plate 2C301-20-2
4 (21-1). Detail B VI4
Visually inspect weld between cap

plate (2C301-21-3) to support
5 post, item 9. MT examine. Detail D MT16
6 Visually inspect all welds VI4
7 Check material of piece 8
Visually inspect welds attaching

8 23-6 in top view. MT examine MT16
2C301-22-0
9 Check item 9 material. Side view
Visually inspect weld connecting

23-5 to 23-1 and item 1. MT
10 examine. Side view MT16
Visually inspect welds at joints
between pieces 111-1, -2, &-3.
11 Detail C VI4
piece 111-4 to gussets & 111-1.
12 End view VI4
2C301-24-1
Visually inspect welds 8 to 111-1,
13 111-2 and items 2 &3. Detail B
Visually inspect welds 2 to 3.
14 Detail B
Visually inspect welds 115-A to
15 111-2. Front view
ITP-2C301
Leged: H = Hold, W = Witness, R = Review, S = Surveillance Rev1-12/02/08
Form Number: CMS-720-01-FM-00291 Page 1 of 9
16 piece 2 to 1. Section A 2C301-29-3
17 Check hole drilled in piece 9
Check material of pieces 1, 9 and 2C301-80-6
18 11
piece 2 to 1. MT examine. Top
19 view
2C301-81-1

20 piece 12 to 1 (A). MT examine
21 Check material of piece 6 2C301-85-3
Visually inspect welds attaching 2C301-86-3

22 piece 115-B to carriage. Top view
23 Visually inspect all welds 2C301-88-1
piece 5 to 4, lug to ladder. Side
2C301-89-1
24 view
25 Check material of of piece 6.

26 pieces 9 & 12 to 1. Side view
Check welds attaching pieces 1 to 2C301-96-2
27 2
Check welds attaching pieces 3 to
28 2 (A).

31 piece 115-B to carriage. Top view
32 pieces 2 to 3. Detail D
pieces 2 & 3 & 5 together. Top
33 view
ITP-2C301
Leged: H = Hold, W = Witness, R = Review, S = Surveillance Rev1-12/02/08
Drawing: 2C301-19-1 Drawing: 2C301-20-2
Activity 1 Activity 3
Check material and length of piece 14
Drawing: 2C301-20-2
Activity 4
Visually Inspect welds attaching piece 121-2 to 121-1. Front view
Drawing: 2C301-20-2
Activity 2
Visually inspect aluminum welds attaching toe boards to floor plate (21-1).
Detail B
Drawing: 2C301-20-2
Activity 5
Visually inspect all welds Visually inspect welds attaching 21-3 to item 9.
MT examine. Detail D
ITP-2C301
Leged: H = Hold, W = Witness, R = Review, S = Surveillance REV1 -12/02/08
Visually inspect welds attaching 23-6 in top view. MT examine
Drawing: 2C301-22-0
Activity 9
Visually inspect all welds Check item 9 material. Side view

Check material of piece 8
Visually inspect welds connecting 23-5 to 23-1 and item 1. MT examine.

Side view
ITP-2C301
Visually inspect welds item 8 to 111-1, 111-2 and items 2 & 3. Detail B
Visually inspect welds at joints between pieces 111-1, -2, &-3. Detail C

Visually inspect welds 2 to 3. Detail B
Visually inspect welds attaching piece 111-4 to gussets & 111-1. End view
ITP-2C301
Visually inspect welds 115-A to 111-2. Front view
Drawing: 2C301-29-3
Activity 16
Check material of pieces 1, 9 and 11.
Drawing: 2C301-81-1
Activity 19
Visually inspect welds attaching piece 2 to 1. Section A

Visually inspect welds attaching piece 2 to 1. MT examine. Top view
Drawing: 2C301-29-3
Activity 17
Drawing: 2C301-81-1
Activity 20
Check hole drilled in piece 9 Visually inspect weld piece 12 to 1. MT examine. Detail A
ITP-2C301
Drawing: 2C301-85-3 Drawing 2C301-89-1
Check material of piece 6.
Drawing 2C301-86-3 Visually inspect welds attaching piece 5 to 4, lug

Activity 22 to ladder. Side View
Visually inspect welds attaching piece 115-B to carriage. Top View

Drawing 2C301-89-1
Drawing 2C301-88-1 Activity 25
Activity 23 NOTE: PIECE IS NOT LABELED ON DRAWING
Check material of piece 6
Drawing: 2C301-96-2
Activity 26
Visually inspect all welds Visually inspect welds attaching pieces 9 & 12 to
1. Side view
ITP-2C301
Visually inspect welds attaching pieces 1 to 2
Drawing: 2C301-96-2
Activity 28
Visually inspect all welds
Drawing: 2C301-98-4
Activity 30
Visually inspect welds attaching pieces 3 to 2 (A).
Visually inspect all welds
ITP-2C301
Drawing: 2C301-114-1
Activity 31
Visually inspect welds attaching piece 115-B to carriage. Top View

Visually inspect welds attaching pieces 2 & 3 & 5 together. Top view
Visually inspect welds attaching pieces 2 to 3. Detail D
ITP-2C301
Document Id.: ITP-2C301-Long
INSPECTION AND TEST PLAN DETAIL Revision: -
Project Name: 2C301-Long Kit Fabrication Contract No.: -
Activity Controlling Document Resp. Acceptance Recording Inspection Involvement

Activity Description CB&I
Remarks
No. Party Criteria Document CB&I Client Third Party
Spec. Proc. Dwg. QC
1 Visually Inspect all welds VI4
Verify flush grinding of plug
welds between 2C301-185-1 and
2 2C301-185-2
Verify hole patterns on 2C301-29- 2C301-185

3 1, 2C301-185-2, and 2C301-185-4
Verify vertical slide 2C301-19-A
moves across splice between
2C301-29-A and 2C301-185-1
4 without undue interference
Legend: H = Hold, W = Witness, R = Review, S = Surveillance
Form Number: CMS-720-01-FM-00291 Issued for Use: 15 Jul 2008 Page 1 of 1

AVW – 300/301 Manual Part Appx B
Appendix B – Applicable Drawings Page 1
Appendix B – Applicable Drawings
1. AVW MPS Hookup

a. AVW 300/ 301
2. AVW Master Hookup Diagram

a. AVW 300
b. AVW 301
3. AVW Wiring Diagram

a. AVW 300
b. AVW 301
4. Fume Extractor Kit

AVW – 300/301 Manual Part Appx C
Appendix C – Vendor Documents Page 1
Appendix C – Vendor Documents
1. Drive System
Baldor Motor Manual
Baldor Control Manual
Electa-Gear Gear Box Manual
2. Wire Feed System

LN-10 Wire feeder
-Pages 37-51 from manual are attached.
Wire Straightener
-K1733-1
Gullco Oscillator Manual
Veeder-Root Rate Meter

-Series C628 Rate Meter
3. Proteus Flow Switch

Data Sheet
Technical Reference Manual
4. AVW MPS Power Sources

Miller 800 Manual
Miller 801D Manual
Note: The linked documents in this manual can also be reached through the CCT Page on
CBIKnowHow.
Integral Horsepower
DC Motor
Installation & Operating Manual
2/09 MN605
Any trademarks used in this manual are the property of their respective owners.
Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Lifting Magnet Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Preparation for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Removal From Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2
Installation & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Doweling & Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Conduit Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Coupled Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Section 3
Maintenance & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lubrication & Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Type of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Brush Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Poor Brush Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Brush Chatter or Bounce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Brush Sparking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Carbon Brushes For Special Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Authorized Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Humidity And Brush Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Continued on next page
MN605 Table of Contents i

Guide To Commutator Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Rapid Commutator Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Turning The Commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Commutator Undercutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Blowers & Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Armature Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Field Coil Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Excessive Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Jogging and Repeated Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Reflash Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Section 4
Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
ii Table of Contents MN605

Section 1
General Information
Overview This manual contains general procedures that apply to Baldor Motor products. Be sure to read and
understand the Safety Notice statements in this manual. For your protection, do not install, operate or
attempt to perform maintenance procedures until you understand the Warning and Caution statements.
A Warning statement indicates a possible unsafe condition that can cause harm to personnel.
A Caution statement indicates a condition that can cause damage to equipment.
Important: This instruction manual is not intended to include a comprehensive listing of all details for all
procedures required for installation, operation and maintenance. This manual describes general
guidelines that apply to most of the motor products shipped by Baldor. If you have a question
about a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldor
distributor for more information or clarification.
Before you install, operate or perform maintenance, become familiar with the following:
S NEMA Publication MG 2, Safety Standard for Construction and guide
for Selection, Installation and Use of Electric Motors and Generators.
S The National Electrical Code
S Local codes and Practices
Limited Warranty
www.baldor.com/support/warranty_standard.asp
Safety Notice: This equipment contains high voltage! Electrical shock can cause serious or fatal injury. Only qualified
personnel should attempt installation, operation and maintenance of electrical equipment.
Be sure that you are completely familiar with NEMA publication MG 2, safety standards for construction
and guide for selection, installation and use of electric motors and generators, the National Electrical
Code and local codes and practices. Unsafe installation or use can cause conditions that lead to serious
or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this
equipment.
WARNING: Do not touch electrical connections before you first ensure that power has been disconnected.
Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
WARNING: Disconnect all electrical power from the motor windings and accessory devices before
disassembly of the motor. Electrical shock can cause serious or fatal injury.
WARNING: Be sure the system is properly grounded before applying power. Do not apply power before you
ensure that all grounding instructions have been followed. Electrical shock can cause serious or
fatal injury. National Electrical Code and Local codes must be carefully followed.
WARNING: Avoid extended exposure to machinery with high noise levels. Be sure to wear ear protective
devices to reduce harmful effects to your hearing.
WARNING: Surface temperatures of motor enclosures may reach temperatures which can cause discomfort
or injury to personnel accidentally coming into contact with hot surfaces. When installing,
protection should be provided by the user to protect against accidental contact with hot surfaces.
Failure to observe this precaution could result in bodily injury.
WARNING: This equipment may be connected to other machinery that has rotating parts or parts that are
driven by this equipment. Improper use can cause serious or fatal injury. Only qualified
personnel should attempt to install operate or maintain this equipment.
WARNING: Do not by-pass or disable protective devices or safety guards. Safety features are designed to
prevent damage to personnel or equipment. These devices can only provide protection if they
remain operative.
WARNING: Avoid the use of automatic reset devices if the automatic restarting of equipment can be
hazardous to personnel or equipment.
WARNING: Be sure the load is properly coupled to the motor shaft before applying power. The shaft key
must be fully captive by the load device. Improper coupling can cause harm to personnel or
equipment if the load decouples from the shaft during operation.
WARNING: Use proper care and procedures that are safe during handling, lifting, installing, operating and
maintaining operations.
Improper methods may cause muscle strain or other harm.
WARNING: UL listed motors must only be serviced by authorized Baldor Service Centers if these motors are
to be returned to a flammable and/or explosive atmosphere.
MN605 General Information 1-1

Safety Notice Continued
WARNING: Pacemaker danger − Magnetic and electromagnetic fields in the vicinity of current carrying
carrying conductors and permanent magnet motors can result result in a serious health hazard to
persons with cardiac pacemakers, metal implants, and hearing aids. To avoid risk, stay way from
the area surrounding a permanent magnet motor.
WARNING: Before performing any motor maintenance procedure, be sure that the equipment connected to
the motor shaft cannot cause shaft rotation. If the load can cause shaft rotation, disconnect the
load from the motor shaft before maintenance is performed. Unexpected mechanical rotation of
the motor parts can cause injury or motor damage.
WARNING: Use only UL/CSA listed explosion proof motors in the presence of flammable or combustible
vapors or dust.
WARNING: Motors that are to be used in flammable and/or explosive atmospheres must display the UL label
on the nameplate along with CSA listed logo. Specific service conditions for these motors are
defined in NFPA 70 (NEC) Article 500.
WARNING: Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
WARNING: Thermostat contacts automatically reset when the motor has slightly cooled down. To prevent
injury or damage, the control circuit should be designed so that automatic starting of the motor is
not possible when the thermostat resets.
Caution: To prevent premature equipment failure or damage, only qualified maintenance personnel should
perform maintenance.
Caution: Do not over−lubricate motor as this may cause premature bearing failure.
Caution: Do not over tension belts. Excess tension may damage the motor or driven equipment.
Caution: Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware
is adequate for lifting only the motor. Disconnect the load from the motor shaft before moving the
motor.
Caution: If eye bolts are used for lifting a motor, be sure they are securely tightened. The lifting direction
should not exceed a 20° angle from the shank of the eye bolt or lifting lug. Excessive lifting
angles can cause damage.
Caution: To prevent equipment damage, be sure that the electrical service is not capable of delivering more
than the maximum motor rated amps listed on the rating plate.
Caution: If a HI POT test (High Potential Insulation test) must be performed, follow the precautions and
procedure in NEMA MG 1 and MG 2 standards to avoid equipment damage.
Caution: Series wound motors must never be allowed to run with no load (broken belt etc.)
An unloaded motor may reach destructive high speeds.
Caution: Do not use Silicone grease or Sealing Compounds (RTV) on or in the vicinity of the motor or its air
supply. Silicone vapor inside the motor will result in extremely rapid brush wear.
Caution: Motors designed for forced ventilation must have cooling air when fields are excited at rated
voltage. Installations having the air supply interrupted when the motor is not operating must have
field disconnected or field voltage reduced to 67% rated by means of field economizing resistor
and relay or motor insulation life will be significantly reduced.
If you have any questions or are uncertain about any statement or procedure, or if you require additional
information please contact your Baldor distributor or an Authorized Baldor Service Center.
Receiving Each BaldorSReliance motor is thoroughly tested at the factory and carefully packaged for shipment.
When you receive your motor, there are several things you should do immediately.
1. Observe the condition of the shipping container and report any damage immediately to the
commercial carrier that delivered your motor.
2. Verify that the part number of the motor you received is the same as the part number listed on your
purchase order.
Lifting Magnet Generators Treat Baldor lifting magnet generators like motors during installation or maintenance.
Generally, they have standard compound self-excited fields. Standard magnetism is for counter-clockwise
rotation (facing the drive end of the motor). To reverse (operate clockwise), refer to the connection
diagrams in Section 4 of this manual.
1-2 General Information MN605

is adequate for lifting only the motor. Disconnect the load from the motor shaft before moving the
motor.
Handling The motor should be lifted using the lifting lugs or eye bolts provided.
1. Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the motor and additional
equipment connected to the motor by this method. The lugs or eye bolts provided are designed to lift
only the motor. Never lift the motor by the motor shaft or the hood of a WPII motor. If eye bolts are
used for lifting a motor, be sure they are securely tightened. The lifting direction should not exceed a
20° angle from the shank of the eye bolt. Excessive lifting angles can cause motor damage.
2. To avoid condensation inside the motor, do not unpack until the motor has reached room temperature.
(Room temperature is the temperature of the room in which it will be installed).
The packing provides insulation from temperature changes during transportation.
3. When lifting a WPII (Weather Proof Type 2) motor, do not lift the motor by inserting lifting lugs into
holes on top of the cooling hood. These lugs are to be used for hood removal only.
A spreader bar should be used to lift the motor by the cast lifting lugs located on the motor frame.
4. If the motor must be mounted to a plate with the driven equipment such as pump, compressor etc.,
it may not be possible to lift the motor alone. For this case, the assembly should be lifted by a sling
around the mounting base. The entire assembly can be lifted as an assembly for installation.
Do not lift the assembly using the motor lugs or eye bolts provided. Lugs or eye bolts are designed to
lift motor only. If the load is unbalanced (as with couplings or additional attachments) additional slings
or other means must be used to prevent tipping. In any event, the load must be secure before lifting.
Storage Storage requirements for motors and generators that will not be placed in service for at least six months
from date of shipment. To avoid condensation inside the motor, do not unpack until the motor has
reached room temperature. (Room temperature is the temperature of the room in which it will be
installed). The packing provides insulation from temperature changes during transportation.
Improper motor storage will result in seriously reduced reliability and failure. An electric motor that does
not experience regular usage while being exposed to normally humid atmospheric conditions is likely to
develop rust or rust particles on surrounding surfaces to contaminate the bearings. The electrical
insulation may absorb an excessive amount of moisture leading to the motor winding failure.
A wooden crate “shell” should be constructed to secure the motor during storage. This is similar to an
export box but the sides & top must be secured to the wooden base with lag bolts (not nailed as export
boxes are) to allow opening and reclosing many times without damage to the “shell”.
Preparation for Storage
1. Some motors have a shipping brace attached to the shaft to prevent damage during transportation.
The shipping brace, if provided, must be removed and stored for future use. The brace must be
reinstalled to hold the shaft firmly in place against the bearing before the motor is moved.
2. Store in the original containers in a clean, dry, protected warehouse where these controlled:
a. Shock or vibration must not exceed 2 mils maximum at 60 hertz, to prevent the bearings from
brinelling. If shock or vibration exceeds this limit vibration isolation pads must be used.
b. Storage temperatures of 10°C (50°F) to 49°C (120°F) must be maintained.
c. Relative humidity must not exceed 60%.
d. Motor space heaters (optional) are to be connected and energized whenever there is a possibility
that the storage ambient conditions will reach the dew point. Space heaters are optional.
Note: Remove motor from containers when heaters are energized, reprotect if necessary.
3. Measure and record the resistance of the winding insulation every 30 days of storage.
a. If motor insulation resistance decreases to less than 5 Meg ohms, contact your Baldor District
office.
b. Place new desiccant inside the vapor bag and re−seal by taping it closed.
c. If a zipper−closing type bag is used instead of the heat−sealed type bag, zip the bag closed
instead of taping it. Be sure to place new desiccant inside bag after each monthly inspection.
d. Place the shell over the motor and secure with lag bolts.
4. Where motors are mounted to machinery, the mounting must be such that the drains and breathers
are fully operable and are at the lowest point of the motor. Vertical motors must be stored in the
vertical position. Storage environment must be maintained as stated in step 2.
MN605 General Information 1-3

5. Motors with anti−friction bearings are to be greased at the time of going into extended storage with
periodic service as follows:
a. Motors marked “Do Not Lubricate” on the nameplate do not need to be greased before or during
storage.
b. Ball and roller bearing (anti−friction) motor shafts are to be rotated manually every 3 months and
greased every 6 months in accordance with the Maintenance section of this manual.
c. Sleeve bearing (oil lube) motors are drained of oil prior to shipment. The oil reservoirs must be
refilled to the indicated level with the specified lubricant, (see Maintenance). The shaft should be
rotated monthly by hand at least 10 to 15 revolutions to distribute oil to bearing surfaces.
d. “Provisions for oil mist lubrication” – These motors are packed with grease.
Storage procedures are the same as paragraph 5b.
e. “Oil Mist Lubricated” – These bearings are protected for temporary storage by a corrosion
inhibitor. If stored for greater than 3 months or outdoor storage is anticipated, connected to the oil
mist system while in storage. If this is not possible, add the amount of grease indicated under
“Standard Condition” in Section 3, then rotate the shaft 15 times by hand.
6. All breather drains are to be fully operable while in storage (drain plugs removed). The motors must
be stored so that the drain is at the lowest point. All breathers and automatic “T” drains must be
operable to allow breathing and draining at points other than through the bearings around the shaft.
Vertical motors should be stored in a safe stable vertical position.
7. Coat all external machined surfaces with a rust preventing material.
An acceptable product for this purpose is Exxon Rust Ban # 392.
8. Carbon brushes should be lifted and held in place in the holders, above the commutator, by the brush
holder fingers. The commutator should be wrapped with a suitable material such as cardboard paper
as a mechanical protection against damage.
Non−Regreaseable Motors
Non−regreasable motors with “Do Not Lubricate” on the nameplate should have the motor shaft rotated
15 times to redistribute the grease within the bearing every 3 months or more often.
All Other Motor Types
Before storage, the following procedure must be performed.
1. Remove the grease drain plug, if supplied, (opposite the grease fitting) on the bottom of each bracket
prior to lubricating the motor.
2. The motor with regreasable bearing must be greased as instructed in Section 3 of this manual.
3. Replace the grease drain plug after greasing.
4. The motor shaft must be rotated a minimum of 15 times after greasing.
5. Motor Shafts are to be rotated at least 15 revolutions manually every 3 months and additional grease
added every nine months (see Section 3) to each bearing.
6. Bearings are to be greased at the time of removal from storage.
Removal From Storage
1. Remove all packing material.
2. Measure and record the electrical resistance of the winding insulation resistance meter at the time of
removal from storage. The insulation resistance must not be less than 50% from the initial reading
recorded when the motor was placed into storage. A decrease in resistance indicates moisture in the
windings and necessitates electrical or mechanical drying before the motor can be placed into
service. If resistance is low, contact your Baldor District office.
3. Regrease the bearings as instructed in Section 3 of this manual.
4. Reinstall the original shipping brace if motor is to be moved. This will hold the shaft firmly against the
bearing and prevent damage during movement.
1-4 General Information MN605

Section 2
Installation & Operation
Overview Installation should conform to the National Electrical Code as well as local codes and practices.
When other devices are coupled to the motor shaft, be sure to install protective devices to prevent future
accidents. Some protective devices include, coupling, belt guard, chain guard, shaft covers etc.
These protect against accidental contact with moving parts. Machinery that is accessible to personnel
should provide further protection in the form of guard rails, screening, warning signs etc.
Caution: Do not use Silicone grease or Sealing Compounds (RTV) on or in the vicinity of the motor or its air
supply. Silicone vapor inside the motor will result in extremely rapid brush wear.
Location The motor should be installed in an area that is protected from direct sunlight, corrosives, harmful gases
or liquids, dust, metallic particles, and vibration. Exposure to these can reduce the operating life and
degrade performance. Be sure to allow clearance for ventilation and access for cleaning, repair, service
and inspections. Ventilation is extremely important. Be sure the area for ventilation is not obstructed.
Obstructions will limit the free passage of air. Motors get warm and the heat must be dissipated to
prevent damage.
These motors are not designed for atmospheric conditions that require explosion proof operation.
They must NOT be used in the presence of flammable or combustible vapors or dust.
TEFC motors can be used for indoor or outdoor standard service. They cannot be used outdoors where
they would be exposed to freezing rain. Standard TEFC motors are not designed for atmospheric
conditions requiring explosion-proof operation, such as flammable or combustible vapors or dust.
is adequate for lifting only the motor. Disconnect the load (gears, pumps, compressors, or other
driven equipment) from the motor shaft before lifting the motor.
Mounting The motor must be securely installed to a rigid foundation or mounting surface to minimize vibration and
maintain alignment between the motor and shaft load. Failure to provide a proper mounting surface may
cause vibration, misalignment and bearing damage.
Foundation caps and sole plates are designed to act as spacers for the equipment they support. If these
devices are used, be sure that they are evenly supported by the foundation or mounting surface.
After installation is complete and accurate alignment of the motor and load is accomplished, the base
should be grouted to the foundation to maintain this alignment.
The standard motor base is designed for horizontal or vertical mounting. Adjustable or sliding rails are
designed for horizontal mounting only. Consult your Baldor distributor or authorized Baldor Service
Center for further information.
Alignment Accurate alignment of the motor with the driven equipment is extremely important.
1. Direct Coupling
For direct drive, use flexible couplings if possible. Consult the drive or equipment manufacturer for
more information. Mechanical vibration and roughness during operation may indicate poor alignment.
Use dial indicators to check alignment. The space between coupling hubs should be maintained as
recommended by the coupling manufacturer.
2. End-Play Adjustment
The axial position of the motor frame with respect to its load is also extremely important. The motor
bearings are not designed for excessive external axial thrust loads. Improper adjustment will cause
failure.
3. Pulley Ratio
The pulley ratio should not exceed 8:1. Consult your Baldor distributor or authorized Baldor Service
Center for further information.
Caution: Do not over tension belts. Excess tension may damage the motor or driven equipment.
4. Belt Drive
Refer to NEMA MG 1 section 14.07 or Baldor application section for the application of pulleys,
sheaves, sprockets, and gears. Align sheaves carefully to minimize belt wear and axial bearing loads
(see End-Play Adjustment). Belt tension should be sufficient to prevent belt slippage at rated speed
and load. However, belt slippage may occur during starting. Do not over-tension belts.
MN605 Installation & Operation 2-1

Doweling & Bolting After proper alignment is verified, dowel pins should be inserted through the motor feet into the
foundation. This will maintain the correct motor position should motor removal be required. (Baldor
motors are designed for doweling.)
1. Drill dowel holes in diagonally opposite motor feet in the locations provided.
2. Drill corresponding holes in the foundation.
3. Ream all holes.
4. Install proper fitting dowels.
5. Mounting bolts must be carefully tightened to prevent changes in alignment. Use a flat washer and
lock washer under each nut or bolt head to hold the motor feet secure. Flanged nuts or bolts may be
used as an alternative to washers.
WARNING: Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
Guarding Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused shaft
extensions. This is particularly important where the parts have surface irregularities such as keys, key
ways or set screws. Some satisfactory methods of guarding are:
1. Covering the machine and associated rotating parts with structural or decorative parts of the driven
equipment.
2. Providing covers for the rotating parts. Covers should be sufficiently rigid to maintain adequate
guarding during normal service.
Power Connection Motor and control wiring, overload protection, disconnects, accessories and grounding should
conform to the National Electrical Code and local codes and practices. Ground the motor by attaching a
strap from an established ground point to the grounding bolt provided inside the conduit box.
Conduit Box For ease of making connections, an oversize conduit box is provided. The box can be rotated 360°
in 90° increments.
Power Connect the motor leads as shown on the connection diagram located on the name plate or inside the
cover on the conduit box. Be sure the following guidelines are met:
1. DC power is within ±5% of rated voltage (not to exceed 600VDC). (See motor name plate for ratings).
OR
2. DC field power is within ±1% of rated voltage.
Motor Connections Terminal connections should be made as specified. See the connection diagrams located in
Section 4 of this manual. Tables 2−1 and 2−2 show the NEMA standard lead markings and the Accessory
Markings.
Table 2−1 NEMA Standard Lead Markings
Lead Markings Motor
Armature A1, A2
Field (shunt) F1, F2, F3, F4, etc.
Field (series) S1, S2
Thermostat P1, P2, etc.
Space Heater H1, H2, H3, H4, etc.
Resistance Temperature Detector (RTD) R1, R2, R3, R4, etc.
Optional Brush Monitor System A1Probe, A2Probe
2-2 Installation & Operation MN605

Table 2−2 Accessory Markings
DC Tachometers + —
XPY 1 2 G
XC Red (1) Black (2) G
NCS Pancake Red Black
AC Tachometers 45/90V Output
45V Red White
90V Red Black
Brake Coil Leads B1, B2, B3, etc.
Space Heater (Brake) H1, H2, H3, H4, etc.
Brake Interlock Switch BS1, BS2, BS3, etc.
Figure 2-1 Encoder Connections

Color Codes for Optional
Baldor Encoder Cable
A A H A B
Electrically H A
Isolated B B
Encoder
J B G K J C
C C
K C
F E D
D +5V
F COMMON
Standard Receptacle MS3112W12−10P E
Standard Plug MS3116J12−10S
Thermostats The thermostat is a pilot circuit device used in a protective relay circuit. The thermostat ratings are given
in Table 2−3.
Table 2−3 Thermostat Ratings
Maximum Current Ratings for Thermostats (Normally Open or Closed Contacts)
Voltage 125VAC 250VAC 24VDC Continuous Current
All Voltages
Amperage 12A 8A 2A 2A

Blower Ventilation System
Before loading a force-ventilated motor, be sure that the blowers, cooling fans, or central air supply
systems are operating properly to supply cooling air to the motor. Air filters should also be in place. If you
energize the main fields with the motor at standstill, the blowers or external cooling systems must be left
on. This will prevent excessive heat buildup that will decrease the life of the insulation.
When using field economy circuits to reduce the voltage to the main fields during standstill, blowers do
not need to be left on.
Blower motors should be checked for correct rotation. Don’t rely on feeling airflow from the drive end of
the motor. Look at the outline drawing or rotation arrow shown on the blower housing. Refer to Figure
2-1.
Figure 2-1 View from Air Inlet (Motor is on Opposite Side)
Air Inlet
Housing
Impeller
Blades
Airflow
Table 2−4 Electrical Data - Forced Ventilation Blower Units

Size Motor Frame HP RPM Volts Phase Hz Amps
LM2 180 1/40 3000 230 1 60 0.4
LM3 180 1/8 3450 115/230 1 50/60 2.6/1.3
LM3 210-250 1/8 3450 208-230/460 3 50/60 0.66-0.60/0.30
LM4 280 1/3 3450 208-230/460 3 50/60 1.5-1.4/0.7
LM6 320-400 1 3450 208-230/460 3 50/60 3.1-3.0/1.5
LM8 504-506 3/4 1750 208-230/460 3 50/60 3.4-3.2/1.6
LM9 508-5012 3 3450 208-230/460 3 50/60 8.2-7.6/3.8
Note: Motor mounted blower units. Mount on commutator end (opposite drive end of motor. We supply
blowers that are powered by totally enclosed motors (standard). Blowers have a cast aluminum fan
housing with washable, wire mesh filters.

Table 2−5 Minimum Blower CFM for DPBV Motors (Drip Proof Blower Ventilated)
Blower Size Motor Frame Size Blower CFM Blower Static Pressure
(In H2O)
LM2 180 55 0.50
LM3 180 150 1.45
LM3 210 175 1.45
LM3 250 215 0.78
LM4 280 350 0.88
LM6 320 780 2.80
LM6 360 780 2.80
LM6 400 820 2.50
LM8 504-506 1120 1.58
LM9 508-5012 2000 5.00
Each motor nameplate is stamped with the above data for DPBV (less Blower),
DPSV and TEPV enclosures.
Caution: Motors designed for forced ventilation must have cooling air when fields are excited at rated
voltage. Installations having the air supply interrupted when the motor is not operating must have
field disconnected or field voltage reduced to 67% rated by means of field economizing resistor
and relay or motor insulation life will be significantly reduced.
Initial Start-Up If driven equipment can be damaged by rotating in the wrong direction, uncouple the motor from the
load before checking for rotation.
If the direction of rotation needs to be corrected, disconnect the input power supply and interchange the
appropriate leads. Refer to the motor connection diagrams in Section 4 of this manual.
1. The first start-up and running of the motor should be with the motor uncoupled from the load.
2. Check the direction of rotation by momentarily applying power to the motor.
3. With the motor running, make sure it’s running smoothly without too much noise or vibration. If either
are present, shut down the motor immediately and find the cause of the problem.
Coupled Start-Up
1. After the first successful no load start-up, stop the motor and assemble the coupling.
2. Align the coupling and be sure it is not binding in any way.
3. The first coupled start-up should be without load. Check to see that the driven equipment is not
transmitting any vibration back to the motor through the coupling or the base. Vibrations (if any)
should be within acceptable levels.
4. Run about 1 hour with driven equipment unloaded.
5. After completing these steps, the motor can now be loaded.
6. Do not exceed the value of armature nameplate amperes under steady continuous loads.

Section 3
Maintenance & Troubleshooting
General Inspection Inspect the motor at regular intervals, approximately every 500 hours of operation or every 3
months, whichever occurs first. Keep the motor clean and the ventilation openings clear. The following
steps should be performed at each inspection:
1. Check that the motor is clean. Check that the interior and exterior of the motor is free of dirt, oil,
grease, water, etc. Oily vapor, paper pulp, textile lint, etc. can accumulate and block motor
ventilation. If the motor is not properly ventilated, overheating can occur and cause early motor
failure.
2. Periodically measure the motor winding resistance to ensure that the integrity of the winding
insulation has been maintained. Record the motor winding resistance. Immediately investigate any
significant drop in insulation resistance.
3. Check all electrical connectors to be sure that they are tight.
4. Check for too much vibration or looseness. It may be caused by improper alignment, an unbalanced
coupling sheave, damaged motor bearings, or loose mounting bolts. Excessive vibration will damage
the motor bearings, brushes and commutator.
5. Listen for unusual noises, especially in the area of the bearings. Also, rubbing or rumbling noises
could be signs of internal damage. Check for loose parts on the motor such as thru bolts, hold down
bolts, bad alignment of hoods, etc. An unbalanced armature or load may also cause noise.
Note: Motors applied with rectified power supplies will often make a humming noise when operating
normally. This is even more noticeable at lower operating speeds. If you can hear a growling or
erratic hum, the power supply should be checked for proper operation and phase balance.
Improper adjustment or functioning of the power supply can cause overheating of the motor and
shorten its life.
6. At start−up, check the tightness of the main and commutating pole bolts (external on the frame) as
listed in Table 3-1. Loose pole bolts could be a source of unpleasant noise when rectified power runs
the motor.
Table 3-1 Torque Specifications for Commutating and Main Pole Bolts
Frame Bolt Size Torque (lb-ft)
180AT 3/8 - 16 24 - 30
210AT 3/8 - 16 24 - 30
250AT 3/8 - 16 24 - 30
280AT 1/2 - 13 60 - 75
320AT 1/2 - 13 60 - 75
360AT 3/8 - 16 24 - 30
400AT 3/8 - 16 24 - 30
500AT 1/2 - 13 60 - 75
MN605 Maintenance & Troubleshooting 3-1

Lubrication & Bearings Bearing grease will lose its lubricating ability over time, not suddenly. The lubricating ability
of a grease (over time) depends primarily on the type of grease, the size of the bearing, the speed at
which the bearing operates and the severity of the operating conditions. Good results can be obtained if
the following recommendations are used in your maintenance program.
Type of Grease A high grade ball or roller bearing grease should be used. Recommended grease for standard
service conditions is Polyrex EM (Exxon Mobil).
Equivalent and compatible greases include:
Texaco Polystar, Rykon Premium #2, Pennzoil Pen 2 Lube and Chevron SRI−2.
− Maximum operating temperature for standard motors = 110° C.

− Shut−down temperature in case of a malfunction = 115° C.
Lubrication Intervals Recommended lubrication intervals are shown in Table 3-2. It is important to realize that the
recommended intervals of Table 3-2 are based on average use.
Refer to additional information contained in Tables 3-3 and 3-4.

Table 3-2 Lubrication Intervals *
Base Speed - RPM
NEMA / (IEC) Frame Size >2500 1750 1150 <800
Up to 210 incl. (132) 5500 Hrs. 12000 Hrs. 18000 Hrs. 22000 Hrs.
Over 210 to 280 incl. (180) 3600 Hrs. 9500 Hrs. 15000 Hrs. 18000 Hrs.
Over 280 to 360 incl. (225) * 2200 Hrs. 7400 Hrs. 12000 Hrs. 15000 Hrs.
Over 360 to 500 incl. (300) *2200 Hrs. 3500 Hrs. 7400 Hrs. 10500 Hrs.
* Lubrication intervals are for ball bearings. For roller bearings, divide the listed lubrication interval by 2.
Table 3-3 Service Conditions
Severity of Service Ambient Temperature Atmospheric Type of Bearing
Maximum Contamination
Standard 40° C Clean, Little Corrosion Deep Groove Ball Bearing
Severe 50° C Moderate dirt, Corrosion Ball Thrust, Roller
Extreme >50° C* or Severe dirt, Abrasive dust, All Bearings
Class H Insulation Corrosion
Low Temperature <-30° C ** All Bearings
* Special high temperature grease is recommended (Dow Corning DC44). Note that Dow Corning DC44 grease does
not mix with other grease types. Thoroughly clean bearing & cavity before adding grease.
** Special low temperature grease is recommended (Aeroshell 7). Different brushes may also be required.
Contact your local Baldor district office or an authorized Baldor service center for technical assistance.
Table 3-4 Lubrication Interval Multiplier
Severity of Service Multiplier
Standard 1.0
Severe 0.5
Extreme 0.1
Low Temperature 1.0
3-2 Maintenance & Troubleshooting MN605

Table 3-5 Bearings Sizes and Types
Frame Size Bearing Description
NEMA (IEC) (These are the “Large” bearings (Shaft End) in each frame size)
Bearing OD Width Weight of Volume of grease
D mm B mm Grease to to be added
add * in3 tea-
oz (Grams) spoon
Up to 210 incl. (132) 6307 80 21 0.30 (8.4 ) 0.6 2.0
Over 210 to 280 incl. (180) 6311 120 29 0.61 (17 ) 1.2 3.9
Over 280 to 360 incl. (225) 6313 140 33 0.81 (23 ) 1.5 5.2
Over 360 to 500 incl. (300) NU319 200 45 2.12 (60) 4.1 13.4
* Weight in grams = .005 DB
Lubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease already
in the motor. Consult your Baldor distributor or an authorized service center if a grease other than the
recommended type is to be used.
Caution: To avoid damage to motor bearings, grease must be kept free of dirt. For an extremely dirty
environment, contact your Baldor distributor or an authorized Baldor Service Center for additional
information.
With Grease Outlet Plug
1. Clean all grease fittings.
2. Remove grease outlet plug.
3. If motor is stopped, add the recommended amount of grease.
If motor is to be greased while running, a slightly greater quantity of grease will have to be added.
Add grease slowly until new grease appears at shaft hole in the endplate or purge outlet plug.
4. Re-install grease outlet plug.
Without Grease Outlet Plug
1. Disassemble motor.
2. Add recommended amount of grease to bearing and bearing cavity. (Bearing should be about 1/3 full
of grease and outboard bearing cavity should be about 1/2 full of grease.)
Note: Bearing is 1/3 full when only one side of bearing is completely full of grease.
3. Assemble motor.
Sample Lubrication Determination
Assume - NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an ambient temperature of
43° C and the atmosphere is moderately corrosive.
1. Table 3-2 list 9500 hours for standard conditions.
2. Table 3-3 classifies severity of service as “Severe”.
3. Table 3-4 lists a multiplier value of 0.5 for Severe conditions.
4. Table 3-5 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added.
Note: Smaller bearings in size category may require reduced amounts of grease.

Brush Replacement Do not change brush grades or suppliers without first contacting Baldor for technical
assistance.
Brush life will vary greatly due to motor load conditions and the operating environment. The brush pigtail
leads should be checked for secure connection to the brush support stud. Brushes should be replaced
when their pigtails touch the top of the brush holder.
When replacing brushes, proper seating is important!
1. Wrap a strip of coarse grit (60) sandpaper, rough side out, around the commutator and under the
brush holder. (Do not use metal oxide based sandpaper or emery cloth that contains electrically
conductive materials).
2. Slide the new brush into the holder and snap the spring clip in place.
3. Rotate the armature slowly in the direction of normal motor rotation.
4. Remove the brush and inspect the face. The brush should be seated over 90% of the face area and
completely seated from leading to trailing edge.
Brushes should move freely in their holders. If brushes stick, it is usually due to built up dirt and oil.
Brushes should be inspected on occasion to see that they are long enough to press firmly against the
commutator. Brush springs should have equal tension. Only brushes of the same size, grade and shape
as those originally supplied should be used.
All motors have their brushes set on neutral before leaving Baldor’s factory. After replacing the brush
holder, realign it to the factory neutral mark.
When replacing a turned-down commutator in the motor with a new commutator, the brush holder
assembly must be adjusted. Keep 1/16″ clearance between the bottom of the brush holder and
commutator. The brush holder assembly is designed with a nut/bolt guide assembly for ease in
positioning of the brush-box.
During periodic inspections, check that electrical connections are tight and properly insulated.
Brush Springs Brush springs should be inspected for proper tension during brush replacement. If the spring shows
a loss in tension, it should be replaced. Routine replacement of brush springs is recommended with
every third set of brushes.
Poor Brush Life Poor brush life may be caused by overloading, brushes operating at higher than their rated speed, or
very light electrical loads. These can be corrected by using a brush with greater current-carrying capacity
for overloads. Friction-reducing treatments reduce wear on high speed applications. Where light loading is
the cause, the answer may be to remove some brushes from the motor (with multiple brushes per pole).
Another is to install brushes with a higher content of graphite that can handle the lower current and still
film properly. Poor brush life is generally not related to the “softness” or “hardness” of the brush.
Do not change brush grades or the number of brushes per pole. Doing so may void the warranty and
make the motor unsafe to operate. Contact your local Baldor district office or an authorized Baldor
service center for technical assistance.
Brush Chatter or Bounce Brush chatter or bouncing can be caused by vibration from an external source. This may
be a bad gearbox coupling or condition, or insecure mounting of the motor. Stronger carbon grades are
available that provide more capacity for the brush to resist vibration. It is always best to fix the cause of
the problem.
Brush Sparking Excessive sparking of brushes may be due to electrical causes such as an overload or a very
unstable DC power supply. Mechanical causes include a flat spot on the commutator or external vibration.
Changing to a better brush grade, or a split-brush design may be required.

Carbon Brushes For Special Operating Conditions
Sometimes, there are problems if motor operation requires a different design or grade of carbon brush
than what was installed when the motor was built. These special operating conditions include long periods
of operation with loads that are significantly greater or less than rated load capacity. Also, operation in in
the presence of certain chemicals, or extreme temperature and humidity can degrade brush performance.
Generally, poor brush life or commutator wear can occur if one or more of the above conditions exist. The
brush used doesn’t match the operating conditions.
Baldor offers optional brush grades for the above conditions and has replacement brushes available to
retrofit motors. Contact your local Baldor District Office or an Authorized Baldor Service Center for
technical assistance.
make the motor unsafe. Contact your local Baldor district office or an authorized Baldor service center for
Authorized Service Baldor catalog 505 (and the Baldor CD−ROM) lists service shops authorized to service Baldor
DC motors. Contact your local Baldor District Office for more information.
Humidity And Brush Wear This curve represents 2 grains of water per cubic foot of dry air or 4.6 grams per cubic
meter of dry air.
Zone of Safe Brush Operation
110 45
40
100
Temperature Degrees C
Temperature Degrees F
35
90
30
80
25
70
20
60 15
50 Danger Zone 10
Too Low Humidity
40 5
0
30
10 20 30 40 50 60 70 80 90 100
Percent Relative Humidity

Section 1
General Information
Guide To Commutator Appearance
Light Film: Indicates good brush Medium Film: Is the ideal commutator Heavy Film: Results from high load, high
performance. Light load, low humidity, condition for maximum brush and humidity or heavy filming rate grades. Colors
brush grades with low filming rates, or film commutator life. not in the brown tones indicate contamination
reducing contamination can cause lighter resulting in high friction and high resistance.
color.
Streaking: Results from metal transfer to Threading: Is a further development of the Grooving: May result from an overly
the brush face. Light loads and/or light streaking condition as the metal abrasive brush grade. The more common
spring pressure are most common causes. transferred becomes work hardened and cause is poor electrical contact resulting in
Contamination can also be a contributing machines into the commutator surface. arcing and the electrical machining of the
factor. With increased loads and increased spring commutator surface. Increased spring
pressure this condition can be avoided. pressure reduces this electrical wear.
Copper Drag: Develops as the commutator Bar Edge Burning: Results from poor Slot Bar Marking: Results from a fault in
surface becomes overheated and commutation. Check that brush grade has the armature windings. The pattern relates
softened. Vibration or an abrasive grade adequate voltage drop, that the brushes to the number of conductors per slot.
causes the copper to be pulled across the are properly set on neutral and that the
slots. Increased spring pressure will interpole strength is correct.
reduce commutator temperature.
This chart courtesy of Helwig Carbon Products, Inc., Milwaukee, WI

Section 1
General Information
Caution: Be very careful when repainting a drip proof motor. Do not get any paint on the commutator. Paint
on the commutator will show up as black marks in brush tracks. Also, excessive brush sparking
or erratic operation can be caused by paint or other material on the commutator.
Commutator After several hours of operation, the commutator surface under the brush should take on a darker bronze
color. This is due to self-generated film caused by normal commutation. This coloration should be even,
without blotches or black areas. A shiny copper color or black streaks in the brush tracks are signs of
improper commutation or contamination by a foreign material. Contact Baldor for assistance in correcting
these problems.
If the commutator becomes rough and burned, or becomes black, it should be cleaned of dirt and carbon
particles. This can be done by wiping it with a dry, lint-free cloth. Also vacuuming or blowing out the motor
with a dry air supply are suitable cleaning methods. Do not use solvents or cleaning solutions on the
commutator. To remove spots or contamination that will not wipe off, wrap a strip of coarse (60# grit)
sandpaper around the commutator. Then rotate the armature back and forth by hand. Do not use emery
cloth as this contains electrically conductive materials.
Another method of commutator resurfacing is to use a commercially available commutator dressing stone.
This should only be done by trained and experienced people. This stone should be taped or attached to
the end of a stick made of electrically insulated material. The motor should be run at about half speed and
the stone applied lightly to the commutator surface. This operation must be done with no load on the
motor.
The surface of the commutator should be smooth and round. This can be checked while the motor is
running at low speed. Press lightly on one brush with an insulated stick. Do not use a lead pencil as this
contains electrically conductive graphite. If you feel movement of the brush, it suggests a worn or
uneven commutator. The armature must be removed from the motor and the commutator machined by a
qualified repair shop.
Rapid Commutator Wear Light electrical loads and contamination are the usual causes of rapid commutator wear.
Light loading may require the removal of some brushes on motors with multiple brushes per pole.
Sometimes a low current density brush grade is used. There are also brushes that have a mild polishing
action. These prevent certain chemicals, especially chlorine and silicone, from attacking the commutator.
Brushes, are available for use in plastic extruder applications where PVC is present. Usually, you do not
have to change the design or grade of the brushes on new motors unless special operating conditions
exist.
make the motor unsafe. Contact your local Baldor district office or an authorized Baldor service center for
Blowers & Filters Do not use silicone RTV around DC motors as commutator surface damage can occur. Intake filters
on blowers and louvers of drip proof motors should be cleaned to remove any dust or foreign matter.
Canister type filters should be replaced when dirty. Failure to keep air intakes clear will cause overheating
and premature failure of the insulating system.
Troubleshooting
Armature Overheating Excessive overloads will cause a noticeable odor of overheated varnish or charred
insulation. The commutator may eventually become blackened and pitted and the brushes burned. This
overheating may be general and uniform. To cure, remove the overload and rewind or replace armature if
damaged beyond use.
An open-circuited armature coil will cause flashing at the commutator. Two adjacent bars will show severe
burning and a resulting overheated armature. Short-circuited coils or commutator bars may cause local
heating that could destroy the insulation at that spot. This may result in the burning of the armature coils,
banding or commutator bars.
Grounds in the armature circuit may be found by measuring the motor winding resistance. If the armature
is grounded, less than 1 meg ohm is measured.
These tests should be done by experienced and qualified personnel.

Field Coil Overheating The blowers or external cooling systems should be left in operation if the main field
windings remain fully energized with the motor at standstill. Failure to do so may cause too much heat
build-up which could cause reduced insulation life.
When using field economy circuits to reduce voltage to the main fields during standstill, blowers do not
need to be operating. The most common failure with overheated field coils is a short in one or more of the
shunt coils.
Shorted coils show less than half the line voltage for two pole motors. This is with the fields connected for
high voltage (in series). Shorted four pole motor coils will read less than 1/4 of the line voltage with the
coils connected for high voltage (in series).
A grounded coil may cause overheating. This defect may be tested as shown by the ground test for an
armature. With brushes lifted, measure the motor winding resistance. If the armature is grounded, less
than 1 meg ohm is measured.
An open field coil on a motor will cause the armature to have no torque. The motor may run at a very high
speed at no load. The commutator may be flashing. To locate an open coil, apply line voltage to the shunt
coils (brushes lifted). A voltmeter will show no reading across a good coil. It will show about the line
voltage across the open coil.
These tests should be done by experienced and qualified personnel. If you find any of the above defects,
don’t run the motor. First contact your local Baldor District Office or an Authorized Baldor Service Center
for repairs.
Excessive Load Excessive load may be found by checking the DC armature ampere input and comparing it with the
rating on the nameplate. An excessive load may prevent the motor from starting or accelerating to full
load speed. It could finally result in premature failure of the motor or control. Be sure to use an averaging
type ammeter if the motor’s power is coming from a rectifier or SCR control.
Jogging and Repeated Starts
Repeated starts or jogs of motors may reduce the life of the brushes and winding insulation. The heat
produced by excessive starting may be more than what can be dissipated by the motor under a constant
full load conditions. If you must frequently start or jog a motor, you should check the application with the
local Baldor District Office.
Heating Duty cycle and maximum ambient temperature are shown on the nameplate of the motor. If there is any
question about safe operation, contact the local Baldor District Office.
Motor overheating may be caused by improper ventilation, excessive ambient temperature, dirty
conditions or an inoperable blower or dirty filter. Electrical causes may be due to excess current caused
by an overload or over-voltage to the fields.
Thermostat Most stock Baldor DC motors 180 frame and above have a standard temperature-sensing thermostat
mounted to their interpole winding. This normally closed thermostat opens when the temperature limit is
exceeded. Another option available is a normally open thermostat that closes with temperature.
On blower cooled or separately ventilated motors, the protection capabilities of the thermostats are
greatly reduced at low speeds. This is because the interpoles have the same amount of heat transfer
regardless of speed. Armature heat transfer is less at low speed. There is less internal air turbulence at
low speeds causing higher temperatures at the armature.
The thermal time constant for interpoles can be as much as five times longer than the armature’s time
constant. Because of this, the thermostat cannot be relied upon to protect the armature during extreme
overloads lasting a short time.
The ripple of the rectified power supply and manufacturing tolerances of mounting the device affect the
thermostat’s accuracy.
For thermostat contact ratings, refer to Thermostats in Section 2 of this manual.

Section 1
General Information
Table 3-6 Troubleshooting Chart

Symptom Possible Causes Possible Solutions
Motor will not start Usually caused by line trouble, such Check source of power. Check overloads, fuses,
as, single phasing at the starter. controls, etc.
Excessive humming High Voltage. Check input line connections.
Loose pole pieces. Torque the bolts as specified in Table 3-1.
Motor Over Heating Overload. Compare actual amps Locate and remove source of excessive friction in
(measured) with nameplate rating. motor or load.
Reduce load or replace with motor of greater capacity.
Improper ventilation. Check external cooling blower to be sure air is moving
properly across cooling fins.
Check blower for proper direction of rotation.
Check motor brush covers to ensure they are solid on
the commutator end and that they are not louvered.
Check filter for dirt, clean or replace.
Excessive dirt build-up on motor. Clean motor.
Armature rubbing on stator. Check air gap clearance and bearings.
Tighten “Thru Bolts” that hold the endplates to frame.
Torque the pole bolts as specified in Table 3-1.
Field over voltage. Check input voltage.
Full voltage on field with motor Reduce field voltage to 60% with field economy circuit
stopped. in the control.
Grounded winding. Perform dielectric test and repair as required.
Improper connections. Inspect all electrical connections for proper
termination, clearance, mechanical strength and
electrical continuity. Refer to connection diagram.
Bearing Over Heating Misalignment. Check and align motor and driven equipment.
Excessive belt tension. Reduce belt tension to proper point for load.
Excessive end thrust. Reduce the end thrust from driven machine.
Excessive grease in bearing. Remove grease until cavity is approximately 3/4 filled.
Insufficient grease in bearing. Add grease until cavity is approximately 3/4 filled.
Dirt in bearing. Clean bearing cavity and bearing. Repack with correct
grease until cavity is approximately 3/4 filled.
Vibration Misalignment. Check and align motor and driven equipment.
Rubbing between rotating parts and Isolate and eliminate cause of rubbing.
stationary parts.
Armature out of balance. Have armature balance checked are repaired at your
Baldor Service Center.
Resonance. Tune system or contact your Baldor Service Center for
assistance.
Noise Foreign material in air gap or Remove armature and foreign material. Reinstall
ventilation openings. armature. Check insulation integrity. Clean ventilation
openings.
Growling or whining Bad bearing. Replace bearing. Clean all grease from cavity and new
bearing. Repack with correct grease until cavity is
approximately 3/4 filled.

Accessories The following list shows some accessories available through Baldor’s Mod Express or available on
custom manufactured motors. Contact your Baldor supplier for information on each additional accessory
or those listed below.
Bearing RTD
RTD (Resistance Temperature Detector) devices are used to measure or monitor the temperature of
the motor bearing during operation.
Bearing Thermocouples
Used to measure or monitor bearing temperatures.
Bearing Thermostat
Temperature device that activates when bearing temperatures are excessive. Used with an external
circuit to warn of excessive bearing temperature or to shut down a motor.
Blowers with Filters:
Available to increase the constant torque speed range of DPFG motors. This increases the
continuous operating torque range at low speeds.
Brush Wear Indicator:
Provides a warning when the brushes have worn down to the level where they need to be replaced
(before damage to the commutator).
Condensation Drains & Breathers:
Stainless steel drains and separate breathers are available.
Conduit Boxes
Optional conduit boxes are available in various sizes to accommodate accessory devices.
Cord & Plug Assembly
Adds a line cord and plug for portable applications.
Drip Covers
Designed for use when motor is mounted in a vertical position. Contact your Baldor distributor to
confirm that the motor is designed for vertical mounting.
Fan Cover & Lint Screen
To prevent build-up of debris on the cooling fan.
Nameplate
Additional stainless steel nameplates are available.
Roller Bearings
Recommended for belt drive applications with a speed of 1800 RPM or less.
Rotation Arrow Labels
Rotation arrows are supplied on motors designed to operate in one direction only. Additional rotation
arrows are available.
Slide Bases:
Allows easy belt adjustment while maintaining correct pulley and belt alignment.
Space Heater
Added to prevent condensation of moisture within the motor enclosure during periods of shut down or
storage.
Stainless Hardware
Stainless steel hardware is available. Standard hardware is corrosion resistant zinc plated steel.
Tachometers:
DC, AC and digital outputs are available. These can be mounted to our motors or shipped separately.
Tachs help the SCR control achieve more precise speed regulation than by armature feedback alone.
Transparent Brush Inspection:
For easy brush inspection and commutation monitoring without disassembly of the motor.
Winding RTD
RTD (Resistance Temperature Detector) devices are used to measure or monitor the temperature of
the motor winding during operation.
Winding Thermocouples
Used to measure or monitor winding temperatures.
Winding Thermostat
Temperature device that activates when winding temperatures are excessive. Used with an external
circuit to warn of excessive winding temperature or to shut down a motor.

Reflash Instructions Instructions to reflash the residual magnetism for Lifting Magnet Generators only.
These generators are self−exciting. If voltage will not build up, it is possible the residual magnetism is
insufficient to initiate excitation. This procedure is to restore sufficient residual magnetism to self excite.
Note: Loss of residual magnetism can be caused by misconnection (reversing the connections) of F1 and
F4.
1. Disconnect F1 and F4. All other leads may remain connected.
2. Connect 24 to 40VDC power source positive lead to F1 and negative to F4.
DC source may be batteries, a DC welder (not AC) or rectified AC.
3. Drive generator at rated RPM.
4. Measure the voltage across A1 and A2. Voltage should be 150 to 200% of F1 to F4 voltage. When
A1 to A2 voltage level reaches this level (approximately 30 seconds) carefully remove the source
leads, an arc may be present during disconnect.
5. Stop the generator.
6. Reconnect F1 and F4 as shown in the DC Generator Connection Diagram. Rotation is viewed from
opposite drive end (commutator end) A1 is positive for CCW rotation. A2 is positive for CW rotation.
S1 is always negative.
DC Generator Connection Diagram

Shunt Fields Compound Wound Short Shunt Connection
Series Field
ARM COMM Field
Shown for CCW (counterclockwise) rotation, (viewed from opposite drive end or
commutator end). For CW (clockwise) rotation, interchange leads A1 and A2.

Section 4
Connection Diagrams
Low Voltage connection Shunt Field High Voltage connection Shunt Field
F1 F2 F1 F2 F3 F4
F3 F4
Field Reversing Series Motor
Interpole Series Field Interpole Series Field
Armature Armature
A1 A2 S1 S2 A1 A2 S2 S1
+ − + −
Series Motor CCW Rotation Series Motor CW Rotation

(Facing Commutator End) (Facing Commutator End)
Armature Reversing
Compound and Stabilized Motors
Shunt Field Shunt Field
F2 F3 F2 F3
Interpole Series Field Interpole Series Field
Armature Armature
F1 A1 A2 S1 S2 F4 F1 A2 A1 S1 S2 F4
+ − + −
Compound or Stabilized Shunt Motor Compound or Stabilized Shunt Motor

CCW Rotation (Facing Commutator End) CW Rotation (Facing Commutator End)
High Voltage Field Connection High Voltage Field Connection
MN605 Connection Diagrams 4-1

Field Reversing Shunt Motor
Shunt Field
F2 F3
Interpole
Armature
F1 A1 A2 F4
+ −
Shunt Motor CCW Rotation
(Facing Commutator End)
High Voltage Field Connection
Field Reversing Shunt Motor

Shunt Field
F3 F2
Interpole
Armature
F4 A1 A2 F1
+ −
Shunt Motor CW Rotation
High Voltage Field Connection
DC Generator Connection Diagram

Compound Wound Short Shunt Connection
Shunt Field
F1 F2 F3 F4
Series Field
Rheostat
Comm. Field
A1 A2 S2 S1
+ −
CCW Rotation
For CW Rotation, Interchange Leads A1 and A2.
4-2 Connection Diagrams MN605

Baldor District Offices
BALDOR ELECTRIC COMPANY
World Headquarters
P.O. Box 2400 Fort Smith, AR 72901−2400
(479) 646−4711 Fax (479) 648−5792
www.baldor.com
© 2009 Baldor Electric Company All rights reserved. Printed in USA

MN605 2/09
ELECTRA-GEAR
Worm Gear Reducers
Installation, Lubrication
and Maintenance Instructions
New Design Features

New Design Features
Thank you for your purchase of this Electra-Gear product. This redesigned and enhanced product has
many superior features, improved lead times and increased ratings as standard. Most importantly, all of
the upgrades have been made without changing the critical mounting dimensions.
• Improved Leadtimes: A new assembly process flow enables leadtimes as fast as 1 day.
• Single Piece Housing: The single-piece housing has rounded corners, smooth exterior surfaces
and a uniform finish.
• Eliminate Gaskets and Sealants: The new design uses no gaskets or sealants and all covers are
sealed with o-rings to minimize potential leak paths.
• Increased Ratings: The new Electra-Gear product has 25-30% more torque capacity than the
original design to allow smaller case sizes given the same motor size as before.
• Interchangeability to “Industry” Footprint: The new housing will be machinable to match the
bolt pattern and shaft height of many common cast iron worm reducers like Boston Gear,
Browning, Morse, Dodge and even Grove Gear.
Table of Contents
Warning/Caution Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubrication
Standard Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mounting Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Selection Information
Read ALL instructions prior to operating reducer. Injury to personnel or reducer failure may be caused by improper installation,
maintenance or operation.
Written authorization from ELECTRA-GEAR is required to operate or use reducers in man lift or people moving devices.
Check to make certain application does not exceed the allowable load capacities published in the current catalog.
Buyer shall be solely responsible for determining the adequacy of the product for any and all uses to which Buyer shall apply the
product. The application by Buyer shall not be subject to any implied warranty of fitness for a particular purpose.
Safety Alert
WARNING • For safety, Buyer or User should provide protective guards over all shaft extensions and any moving
apparatus mounted thereon. The User is responsible for checking all applicable safety codes in his area and
providing suitable guards. Failure to do so may result in bodily injury and/or damage to equipment.
• Hot oil and reducers can cause severe burns. Use extreme care when removing lubrication plugs and
vents.
• Make certain that the power supply is disconnected before attempting to service or remove any components.
Lock out the power supply and tag it to prevent unexpected application of power.
• Reducers are not to be considered fail safe or self-locking devices. If these features are required, a
properly sized, independent holding device should be utilized. Reducers should not be used as a brake.
• Any brakes that are used in conjunction with a reducer must be sized or positioned in such a way so as to
not subject the reducer to loads beyond the catalog rating.
• Lifting supports including eyebolts are to be used for vertically lifting the gearbox only, with no other
associated attachments or motors.
• Use of an oil with an EP additive on units with backstops may prevent proper operation of the backstop.
Injury to personnel, damage to the reducer or other equipment may result.
• Overhung loads subject shaft bearings and shafts to stress which may cause premature bearing failure and/
or shaft breakage from bending fatigue, if not sized properly.
CAUTION • Test run unit to verify operation. If the unit tested is a prototype, that unit must be of current production.
• If the speed reducer cannot be located in a clear and dry area with access to adequate cooling air supply,
then precautions must be taken to avoid the ingestion of contaminants such as water and the reduction in
cooling ability due to exterior contaminants.
• Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation.
Important Information
In the event of the resale of any of the goods, in whatever form, Resellers/Buyers will include the following language in a
conspicuous place and in a conspicuous manner in a written agreement covering such sale:
The manufacturer makes no warranties or representations, express or implied, by operation of law or otherwise,
as to the merchantability or fitness for a particular purpose of the goods sold hereunder. Buyer acknowledges
that it alone has determined that the goods purchased hereunder will suitably meet the requirements of their
intended use. In no event will the manufacturer be liable for consequential, incidental or other damages. Even
if the repair or replacement remedy shall be deemed to have failed of its essential purpose under Section
2-719 of the Uniform Commercial Code, the manufacturer shall have no liability to Buyer for consequential
damages.
Resellers/Buyers agree to also include this entire document including the warnings above in a conspicuous place and in a
conspicuous manner in writing to instruct users on the safe usage of the product.
This instructions manual should be read together with all other printed information such as catalogs, supplied by Electra-Gear.
Phone: (262) 878-1221 2 Fax: (262) 878-1968

General Operation
1. Run the motor which drives the reducer and check the direction of reducer output rotation. Consult motor nameplate for
instructions to reverse the direction of rotation.
2. Attaching the load: On direct coupled installations, check shaft and coupling alignment between speed reducer and loading
mechanism. On chain/sprocket and belt/pulley installation, locate the sprocket or pulley as close to the oil seal as possible to
minimize overhung load. Check to verify that the overhung load does not exceed specifications published in the catalog.
3. High momentum loads: If coasting to a stop is undesirable, a braking mechanism should be provided to the speed reducer output or
the driven mechanism.
CAUTION The system of connected rotating parts must be free from critical speed, torsional or other type vibration,
no matter how induced. The responsibility for this system analysis lies with the purchaser of the speed
reducer.
Installation
1. Mount the unit to a rigid flat surface using grade 5 or higher fasteners. The mounting fasteners should be the largest standard size that
will fit in the base mounting hole. Shim as required under flange or base feet which do not lie flat against the mounting surface.
2. For shipment, pipe plugs are installed in the unit and a vent plug is packed separately. After mounting the unit in position, remove the
appropriate pipe plug and install the vent plug in the location shown on page 5. On double reduction units both the primary and the
secondary must be vented. Failure to vent the unit can cause premature seal wear or loss of seal and oil. These conditions are not
covered by warranty. Check for correct oil level. Contact the factory for level and vent recommendations on non-standard mounting
positions.
3. Connect motor to speed reducer.
Depending upon gear geometry and operating conditions worm gear reducers may or may not backdrive. Use of a brake or
external holding device is required if any evidence of backdriving is not desired.
Special consideration should be given to high inertia loads connected to the output shaft. Consult the factory for further details.
WARNING DO NOT CHANGE MOUNTING POSITIONS WITHOUT CONTACTING FACTORY.
Altering the mounting position may require special lubrication provisions which must be factory installed.
CAUTION Do not operate the reducer without making sure it contains the correct amount of oil. Do not overfill or
underfill with oil, or injury to personnel, reducer or other equipment may result.
CAUTION A unit cannot be used as an integral part of a machine superstructure which would impose additional
loads on the unit other than those imposed by the torque being transmitted either through a shaft-
mounted arrangement, and any shaft mounted power transmitting device. (e.g., sprockets, pulleys,
couplings)
CAUTION For safe operation and to maintain the unit warranty, when changing a factory installed fastener for any
reason, it becomes the responsibility of the person making the change to properly account for fastener
grade, thread engagement, load, tightening torque and the means of torque retention.
Lubrication - Standard Units

All standard reducers ordered from the factory are filled with Mobil 460 polyglycol (PAG) lubricant or equivalent suitable for continuous
option within a -10° F to 120° F ambient temperature range. Double and triple reduction units have separate oil sumps and must be filled/
checked independently. Prior to startup, verify that the oil is at the level shown on the drawings on page 6.
Change Intervals: Standard compounded lubricants (non-synthetic) should be changed every six months or 2500 operating hours,
whichever comes first. Factory installed synthetic lubricants should be changed only when performing maintenance that requires gearbox
disassembly.
CAUTION Oil should be changed more often if reducer is used in a severe environment (i.e. dusty, humid).
CAUTION In the Food and Drug Industry (including animal food), consult the lubrication supplier for recommendation of
lubricants which are acceptable to the Food and Drug Administration and/or other authoritative bodies having
jurisdiction. Factory supplied PAG oil is acceptable for incidental food contact (NSF H1) for use in and around food
processing areas.
CAUTION Do not mix different oils in the reducer. Electra-Gear reducers are shipped standard with PAG lubricant – this
lubricant is not compatible with conventional mineral or PAO synthetic oils.
Phone: (262) 878-1221 3 Fax: (262) 878-1968

Special Lubrication Requirements - Size 818 and Larger
Units shipped from the factory are assembled to properly lubricate all internal components based on a specific assumed mounting
orientation. The factory assumed mounting orientations are given below. If a size 818 or larger unit will be mounted in a different
orientation than listed below, or run with sustained input speeds less than 900 RPM, it should be specified with the order. The unit can
then be modified to assure proper lubrication.
Factory Assumed Mounting Orientation Applicable Unit Styles*

Worm Over B, T, F, H, FH, C, Single Reduction
D, DT, DF, DH, DFH Double Reduction Worm-Worm
DX, DXT, DXH, DXFH, Double Reduction Helical-Worm
TT Triple Reduction Worm-Worm-Worm
Worm Under U Single Reduction

DU Double Reduction Worm-Worm
Vertical Output VL/VH, FE Single Reduction

DVL/DVH, DFE Double Reduction Worm-Worm
DXVL/DXVH, DXFE Double Reduction Helical-Worm
Vertical Input J Single Reduction

DJ Double Reduction Worm-Worm
DXJ Double Reduction Helical-Worm
* Includes “M” and “MQ” versions of all styles listed
The precision-made gears and bearings in Electra-Gear Speed Reducers require high-grade lubricants of the proper viscosity to
maintain trouble-free performance. All standard reducers ordered from the factory are filled with ISO viscosity grade 460 polyglycol
(PAG) lubricant. If oil needs to be added or changed, ONLY compatible polyglycol lubricants should be used. Contact the factory
for more information.
Oil Capacities (ounces) - Standard Units

Mounting UNIT SIZE
Position 813 815 818 821 824 826 830 832 842 852 860
1-Worm Over 4 12 12 20 24 40 56 72 112 188 312
2-Worm Under 8 16 20 28 40 60 84 108 152 304 328
3-Vertical Output 4 16 16 28 32 48 68 88 128 248 320
4-Vertical Input 4 16 16 24 32 48 72 92 128 248 325
5-Worm Over on Secondary
Unit of Double Reduction
— — — N/A N/A N/A
N/A 192 308 320 485

16 oz. = 1 pint
2 pints = 1 quart
4 quarts = 1 gallon
1 gallon = 128 oz. = 231 cu. in.
CAUTION Always check for proper oil level after filling. Capacities vary somewhat with model and mounting position.
Oil should rise to bottom edge of level hole. Do not overfill.
CAUTION Do not operate the reducer without making sure it contains the correct amount of oil. Do not overfill or underfill
with oil, or injury to personnel, reducer or other equipment may result.
CAUTION Do not mix different oils in the reducer. Electra Platinum reducers are shipped standard with PAG lubricant –
this lubricant is not compatible with conventional mineral or PAO synthetic oils.
Phone: (262) 878-1221 4 Fax: (262) 878-1968

Standard Speed Reducer Mounting Positions
& Vent Plug, Level and Drain Locations
VENT VENT VENT VENT

LEVEL*
LEVEL LEVEL
LEVEL
DRAIN
DRAIN
Worm Over DRAIN
Vertical Output DRAIN (All primary units have
their own oil level.)
VENT VENT Double Reduction Worm-Worm
LEVEL
LEVEL
*For 4 1/4” through 6” center distance units (far side plug).
Note: High oil level applies to all 4 1/4” center distance & larger secondary
DRAIN & tertiary units regardless of primary unit type.
DRAIN
Worm Under Vertical Input
Maintenance - Standard Units

Your Electra-Gear reducer has been tested and adjusted at the factory. Dismantling or replacement of components must be done by
Electra-Gear to maintain the warranty.
1. Frequently check the oil level of the reducer. If oil level is low, (refer to reducer vent and level position chart) add proper lubrication
through the filler plug until it comes out the oil level plug.
2. Inspect vent plug often to insure it is clean and operating.
3. Always check for proper oil level after filling. Do not overfill or underfill with oil, or injury to personnel, reducer, or other equipment
may result.
4. Do not mix different oils in the reducer.
CAUTION Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation.
Seals: The Electra-Gear line of speed reducers utilizes premium quality seals which are the state-of-the-art in sealing technology. Seals are,
however, a wear item and eventually need to be replaced. Replacement can be easily accomplished by following the steps below:
1. Remove the worn seal without damaging the shaft surface or the seal bore. This can be done by drilling a .062 diameter hole in the
seal casing (being careful not to drill into the bearing behind the seal). Screw a #10 sheet metal screw into the hole and pry out the
seal.
2. Clean the seal bore of sealant.
3. Before installing the new seal, use electrical tape to cover any keyways on the shaft to prevent seal lip damage.
4. Grease the seal lips with bearing grease and apply a sealant to the seal bore.
5. Slide the seal into the shaft being careful not to fold the inner lip over on any shaft steps.
6. Press the seal into its bore with a sleeve that presses on the seal casing, being careful to keep the seal square in its bore.
Lubrication - Electra Platinum

All Electra Platinum reducers are shipped from the factory filled with Mobil 460 polyglycol (PAG) lubricant or equivalent suitable for continuous
operation within a -10° F to 120° F ambient environment. If ambient temperature will be outside the above range, or if operation will be intermittent at
temperatures below 20° F, consult the factory for lubrication recommendations. The unit is factory filled with the correct amount of oil for most
mounting positions. If the unit will operate at input speeds below 900 RPM, or if a 830 or larger unit is to operate with one of its shafts in a
vertical position, consult the factory for special lubrication considerations.
CAUTION In the Food and Drug Industry (including animal food), consult the lubrication supplier for recommendation of
lubricants which are acceptable to the Food and Drug Administration and/or other authoritative bodies having
jurisdiction. Factory supplied PAG oil is acceptable for incidental food contact (NSF H1) for use in and around
food processing areas.
Phone: (262) 878-1221 5 Fax: (262) 878-1968

Maintenance – Electra Platinum
Your Electra Platinum reducer has been tested and adjusted at the factory. Dismantling or replacement of components must be done by
Electra-Gear to maintain the warranty.
Inspect the stem of the internal Enviro-Seal often to ensure it is clean and operating properly. Do not remove nut holding the stem of the
Enviro-Seal to the housing.
Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation.
Seals: The Electra Platinum line of speed reducers utilize premium quality seals which are state-of-the-art in sealing technology. Seals are,
however, a wear item and eventually need to be replaced. Replacement can easily be accomplished by following the procedure given under
Maintenance - Standard Units above. If seal leakage has resulted in the loss of a significant amount of oil, it may be necessary to add more
lubricant. For all worm drives, fill the gearbox to the level indicated in the diagram below.
Standard Oil Level for Electra Platinum

LEVEL LEVEL
~22°
Electra Platinum Oil Fill (ounces)

813 815 818 820 824 826 830 832 842 852
Solid Output Shaft 8 20 24 36 40 72 108 120 208 368
Hollow Output Shaft 8 20 23 30 36 64 96 104 196 316
Class of Service
Load conditions must be within cataloged ratings published in the current Electra-Gear Catalog (available upon request). Published ratings
assume lubrication with ISO 460 viscosity grade polyglycol (PAG) oil. Contact factory for ratings when an alternate lubricant is used.
Warranty From Electra-Gear - See 8050 catalog pages 185-187 for warranty terms and conditions.
1524 15th Avenue • Union Grove, WI 53182

Phone: 262-878-1221 • Fax: 262-878-1968 • www.electragear.com
6414G/1K/3-09/BH/RG
RETURN TO MAIN INDEX
IM587-B
LN-10 Heads & Controls August, 2007
Boom Mount or Bench Models

For use with: LN-10 Control - Boom Mount Code 10442, 10831
10 Series Wire Drive - Boom Mount Code 10443, 10444, 10763, 10764, 10818, 10819
LN-10 Boom Package Code 10445, 10765, 10820
Synergic 7F Drive Code 10190, 10191
LN-10 - Bench Model Code 10440, 10441, 10761, 10762, 10816, 10817
LN-10 - Zipline Boom Package Code 10497, 10498 , 10771, 10772, 10824
Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
Copyright © 2007 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i
SAFETY i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
powered equipment. radiator pressure cap when the engine is

hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ʻ95
ii
SAFETY ii
ELECTRIC SHOCK can ARC RAYS can burn.

kill. 4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
FUMES AND GASES

conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
can be dangerous.
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and 5. b. The operation of welding fume control equipment is affected
welding machine in good, safe operating condition. Replace by various factors including proper use and positioning of
damaged insulation. the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
3.g. Never dip the electrode in water for cooling. exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
3.h. Never simultaneously touch electrically “hot” parts of OSHA PEL and ACGIH TLV limits.
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
of both welders. coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.i. When working above floor level, use a safety belt to protect form phosgene, a highly toxic gas, and other irritating prod-
yourself from a fall should you get a shock. ucts.
3.j. Also see Items 6.c. and 8. 5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
iii
SAFETY iii
WELDING and CUTTING CYLINDER may explode

SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
FOR ELECTRICALLY
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
powered equipment.
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing 8.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate cir- Electrical Code, all local codes and the manufacturerʼs
cuits. This can create fire hazards or overheat lifting chains recommendations.
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturerʼs recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention Jan, 07
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.

iv
SAFETY iv
Mar. ʻ93
v v
for selecting a QUALITY product by Lincoln Electric. We want you

to take pride in operating this Lincoln Electric Company product
Thank You ••• as much pride as we have in bringing this product to you!
CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
vi TABLE OF CONTENTS vi
Page
Installation .......................................................................................................Section A
Technical Specifications .......................................................................................................A-1
General Description..............................................................................................................A-1
Recommended Processes and Equipment ..........................................................................A-2
Installation of the LN-10 Boom Mount Wire Feeder Components ........................................A-2
Mounting the LN-10 Wire Drive Unit .............................................................................A-2
Mounting Synergic 7F Wire Drive Unit (K679-1 or -2)...................................................A-3
Mounting the LN-10 Control Box ..................................................................................A-3
Connecting Wire Drive Unit to Control Box ...................................................................A-3
Electrode Routing..........................................................................................................A-4
Wire Drive Speed Range Selection ......................................................................................A-4
Control Speed Range Setting .......................................................................................A-4
10 Series Wire Drive Ratio Selection ............................................................................A-4
Wire Feed Drive Roll Kits .....................................................................................................A-5
Procedure to Install Drive Roll and Guide Tubes .................................................................A-5
Synergic 7F 4-Roll Kits (KP655 and KP656).................................................................A-5
10 Series Wire Drive Roll Kit Installation ......................................................................A-5
Gun and Cable Assemblies with Standard Connection........................................................A-6
GMAW Guns .................................................................................................................A-6
Innershield Guns ...........................................................................................................A-6
Gun Cable Connection with Standard Connection........................................................A-6
Gun and Cable Assemblies with Fast-Mate Connection ......................................................A-6
GMAW Guns .................................................................................................................A-6
Gun Cable Connection with Fast-Mate Connection ......................................................A-7
Water Connections (For Water Cooled Guns) .....................................................................A-7
10 Series Wire Drives ...................................................................................................A-7
Synergic 7F Drives (K679) ............................................................................................A-7
GMAW Shielding Gas ...................................................................................................A-7
Gas Guard Regulator ....................................................................................................A-7
Electrical Installation.............................................................................................................A-8
Input Cable: LN-10 Control to Power Source ................................................................A-8
Work Cable ...................................................................................................................A-8
Optional Features Installation...............................................................................................A-9
Boom and Bench Conversions.............................................................................................A-9
Operation ............................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
Duty Cycle ............................................................................................................................B-1
LN-10 Control DIP Switch Setup ............................................................................B-1 thru B-5
Keypad and Display Operation ...............................................................................B-6 thru B-9
Dual Procedure Remote Control (K1449-1) ...........................................................................10
Wire Reel Loading ..............................................................................................................B-10
Feeding Electrode and Brake Adjustment..........................................................................B-11
Drive Roll Pressure Setting ................................................................................................B-11
Procedure for Setting Angle of Feedplate ..........................................................................B-12
Gas Guard Regulator Setting .............................................................................................B-12
Making a Weld....................................................................................................................B-12
Wire Reel Changing ...........................................................................................................B-13
Loss of Voltage Sense Shutdown ......................................................................................B-13
Wire Feed Overload Protection ..........................................................................................B-13
Grounding Lead Protector ..................................................................................................B-13
Explanation of Prompting and Error Messages ..................................................................B-14
Accessories .....................................................................................................Section C
Drive Roll and Guide Tube Kits ............................................................................................C-1
Other Optional Features.........................................................................................C-2 thru C-4
Maintenance ....................................................................................................Section D
Safety Precautions ...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Avoiding Wire Feeding Problems .........................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Procedure for Removing Feedplate from Wire Feeder ........................................................D-1
Troubleshooting ..............................................................................................Section E
Safety Precautions ...............................................................................................................E-1
Troubleshooting Procedures .................................................................................E-2 Thru E-8
Procedure for Replacing PC Boards ....................................................................................E-9
vii
TABLE OF CONTENTS
Page ......
Diagrams ..........................................................................................................Section F
Wiring (LN-10 Control) ...........................................................................................F-1
Wiring (10 Series Wire Drive) ................................................................................F-2
Dimension Print......................................................................................................F-3
Parts List ......................................................................................................P311 Series

A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS – LN-10 Heads & Controls

WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER
SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO
Speed Wire Size Speed Wire Size
Solid Cored Solid Cored
K1563-1,-3 10 Series 35-500 IPM .025 - 3/32 in. .035 - .120 in .50 - 750 IPM .025 - 1/16 in. .035 - 5/64 in.
Std Drive Boom Mount (0.89-12.7 M/M) (0.6 - 2.4 mm) (0.9 - 3.0 mm) (1.25 - 19.0 M/M) (0.6 - 1.6 mm) (0.9 - 2.0 mm)
K1563-2,-4 10 Series 55 - 825 IPM .025 - 1/16 in. .035 - 5/64 in. 80 - 1250 IPM .025 - .045 in. .035 - .045 in.
Hi-Speed Boom Mount (1.40 - 21.0 M/M) (0.6 - 1.6 mm) (0.9 - 2.0 mm) (2.00 - 31.8 M/M) (0.6 - 1.2 mm) (0.9 - 1.2 mm)
K679-1 Synergic 7F* 50 - 770 IPM .025 - 1/16 in. .035 - 5/64 in. --- --- ---
Std Drive Boom Mount (1.27 - 19.5 M/M) (0.6 - 1.6 mm) (0.9 - 2.0 mm)
K679-2 Synergic 7F* --- --- --- 80 - 1200 IPM .025 - .045 in. .035 - .045 in.
Hi-Speed Boom Mount (2.00 - 30.5 M/M) (0.6 - 1.2 mm) (0.9 - 1.2 mm)
K1559-1,-3 LN-10 35-500 IPM .025 - 3/32 in. .035 - .120 in. 50 - 750 IPM .025 - 1/16 in. .035 - 5/64 in.
Std Drive Bench Model (0.89-12.7 M/M) (0.6 - 2.4 mm) (0.9 - 3.0 mm) (1.25 - 19.0 M/M) (0.6 - 1.6 mm) (0.9 - 2.0 mm)
K1559-2,-4 LN-10 55 - 825 IPM .025 - 1/16 in. .035 - 5/64 in. 80 - 1250 IPM .025 - .045 in. .035 - .045 in.
Hi-Speed Bench Model (1.40 - 21.0 M/M) (0.6 - 1.6 mm) (0.9 - 2.0 mm) (2.00 - 31.8 M/M) (0.6 - 1.2 mm) (0.9 - 1.2 mm)
CONTROLS, HEADS AND COMPLETE UNITS

SPEC.# TYPE INPUT POWER PHYSICAL SIZE• TEMPERATURE RATING
Dimensions
Height Width Depth Weight Operating Storage
K1562-1∆,-2∆ LN-10 40-42 Vac + 10% 14.80 “ 14.20 “ 4.20 “ 18.0 Lbs
Control Controls 4.0 Amps 50/60 Hz (K1562-1) (375.9 mm) ( 360.7mm) (106.7 mm) (8.2 Kg)
6.0 Amps 50/60 Hz (K1562-2)
K1563-1∆,-3∆ 10 Series 7.81 “ 14.71 “ 11.00“ 25.0 Lbs
K-1563-1,-2
Std Drive Boom Mount (198.4 mm) (373.6 mm) (27.94 mm) (11.3 Kg)
30.0 Lbs
K1563-2,-4 (13.6 Kg) K-1563-3,-4
Hi-Speed +40°C +40°C

to to
K679-1 Synergic 7F* 11.5“ 7.16“ 8.06“ 16.5 Lbs -20°C -40°C
Std Drive Boom Mount ( 285.8mm) (181.9 mm) (204.7mm) (7.5 Kg.)
K679-2 Synergic 7F*

Hi-Speed Boom Mount
K1559-1,-3 LN-10 40-42 Vac + 10% 20.46 “ 14.73 “ 30.35 “ 65.0 Lbs
Std Drive Bench Model 4.0 Amps 50/60 Hz (K1559-1,-2) (519.7 mm) (366.5 mm) (770.9 mm) (29.5 Kg) K-1559-1,-2
6.0 Amps 50/60 Hz (K1559-3,-4) 70.0 Lbs

K-1559-3,-4
K1559-2,-4 (31.8 Kg)
Hi-Speed
• Excluding Wire Reel

∆ Included with K1561-Series, LN-10 Boom Packages
*Synergic 7F wire drives use 4-roll drives with 2 driven rolls(Drive roll kits not common with 10 Series heads)
GENERAL DESCRIPTION
The LN-10 is a modular line of 42VAC input 4-roll wire feed- Also, 4 selectable, presettable timers for each procedure;
ers. A single control with dual procedure presettability of preflow, postflow, burnback and spot weld time.
wire feed speed (in IPM or M/min) and arc voltage is used
with a single DC welding power source. Arc starting can be optimized for each procedure with 5
selectable wire feed acceleration rates, and independent
The LN-10 models have controls providing keypad or control of slower run-in procedure.
remote selectability of either of two procedures.
A gas purge key is provided, as well as cold feed forward
The units offer 4 independently selectable gun trigger and reverse keys with independently adjustable forward
modes for each procedure; cold feed, 2 step and 4-step trig- feed speed setting.
ger and spot weld mode.
LN-10
All of these features are selected with a tactile-feel keypad, The wire type and size range for the wire drive used,
and are set independently using one of two rotating knob and gear ratio change selected, are given in the
encoders, setting levels are displayed on one of two digital Specifications.
LED displays.
Recommended power sources are Lincoln Electric
The 10 Series Wire Drive assemblies include a heavy duty Company constant voltage power sources with 42
head with externally changeable gear ratio and 4 driven roll VAC auxiliary power and a 14-pin connector recepta-
drives housed together in a single combination mounting cle. At the time of printing these include: CV 250,
and connection box. Gun adapters are available to permit CV300-I, CV-300, CV400-I, CV-400, CV500-I, DC-
use with a variety of standard welding guns. 400, DC-600, CV-655, Invertec V300-PRO, V350-
PRO DC-650 PRO and DC- 655.
Available Models:
The DC-250, DC-1000 and the Pulse Power 500 (CV
The LN-10 Wire Feeder system is available configured in mode only) may also be used with the LN-10 if the
both Bench and Boom models. optional K1520-1 115V / 42V Transformer Kit is used.
Bench Models consists of an LN-10 control and a 10 SAFETY PRECAUTIONS

Series wire drive assembly premounted on a platform
ELECTRIC SHOCK can
with a dual 2" O.D. spindle mounting.
Boom Models consist of an LN-10 control and a choice of kill.

wire drives designed to be mounted separately and joined • Turn the input power off at the power source
by available head to control cable assemblies. disconnect switch before attempting to connect
the input power to the LN-10 Control.
The head to control cable assemblies are available in • Only qualified personnel should perform this installation.
two types; one control cable is required for each head: ----------------------------------------------------------------------------------------
K1498-”L” Includes a control cable with a 14-pin

ms style connection on each end, and
INSTALLATION OF THE LN-10
a 3/0 weld cable. Available in lengths BOOM MOUNT WIRE FEEDER
“L” of 16, 20 or 25 ft. (4.9, 6.1 or 7.6 m) COMPONENTS
K681-”L” Same as above but does not include
weld cable available in lengths “L” of Mounting the 10 Series Double Header
12, 16 or 25 ft. (3.6, 4.9 or 7.6 m). Wire Drive
LN-10 Boom Packages (K1564-Series) are also avail- Mount the 10 Series wire drive to the boom or struc-
able which include: ture using the four 5/16-18 threaded mounting holes
located on the bottom of the drive connection box.
• LN-10 Control Box See Figure A.1 for the size and location of the mount-
• 10 Series Wire Drive ing holes. The feed plate assembly is electrically "hot"
• Appropriate length Control and Weld Cables to when the gun trigger is pressed. Therefore, make cer-
connect Control to Wire Drive tain the feed plate does not come in contact with the
• Accessories specific to the Boom package structure on which the unit is mounted.
ordered
The wire drive unit should be mounted so that the
RECOMMENDED PROCESSES AND drive rolls are in a vertical plane so dirt will not collect
EQUIPMENT
in the drive roll area. Pivot the feed plate so it will
point down at an angle so the wire feed gun cable will
not be bent sharply as it comes from the unit. See
The LN-10 Wire Feeder system is recommended for “Procedure for setting angle of Feed Plate” in the
use with solid wire gas-metal-arc or CV Submerged OPERATION section of this manual.
arc processes, as well as cored wire for Outershield
GMA or Innershield processes.
LN-10
5/16-18 THREAD 2.25 CLEARANCE
10.50
.50
FOR 1/4 BOLT
6.00 13.75
11.00
14.00
12.75
10.00
FEED PLATE
DOOR OPEN CLEARANCE
3.00 FOR 1/4 BOLT
BOTTOM FRONT
10.50 5.00 2.63 2.63
FIGURE A.2
14.50
FIGURE A.1
5.25
14.50
Mounting Synergic 7F Wire Drive Unit Connecting Wire Drive Unit to Control Box
(K679-1 or -2) One head to control cable assembly is required. The
Head to Control cable assemblies are available in two
Mount the wire feed unit by means of the insulated types:
mounting bracket attached to the bottom of the gearbox.
Reference L9777 (included with Drive unit) to find the K1498-"L" -Includes a control cable with 14-pin ms-style
size and location of the mounting holes. The gearbox connectors on each end, and a 3/0 weld
assembly is electrically “hot” when the gun trigger is cable (rated 600 amps, 60% duty cycle) to
pressed. Therefore, make certain the gearbox does not route between the wire drive and the control
come in contact with the structure on which the unit is box. Available in lengths "" of 16 ft. (4.9 m),
mounted. 20 ft. (6.1 m) and 25 ft. (7.6 m)
The wire feed unit should be mounted so that the drive K681-"L" - Same as K1498, but does not include weld
rolls are in a vertical plane so dirt will not collect in the cable. Available in lengths "L" of 12 ft (3.6 m),
drive roll area. Position the mechanism so it will point 16 ft (4.9 m) and 25 ft. (7.6 m).
down at about a 45° angle so the wire feed gun cable will
not be bent sharply as it comes from the unit. a) Making certain the cables are protected from any
sharp corners which may damage their jackets,
Note: The K1562-1 control box must be used with the mount the cable assembly along the boom so the end
K679-1 or -2. with the female amphenol connector pins is at the
wire feed unit.
Mounting the LN-10 Control Box
b) Connect the 14-socket cable connectors to the mating
The same control box is used for both a 10 Series drive, receptacles on the back of the wire feed unit connec-
or a Synergic 7F drive. The back plate of the control box tion box.
has two keyhole slots and one bottom slot for mounting.
See Figure A.2 for the size and location of these slots. c) At the same end, connect the electrode lead to the
Mount the box at some convenient location close to the 1/2" connection bolt on the front of the left wire drive
wire drive unit which will enable the desired control cable head feed plate.
to reach between the control box and the wire drive unit.
d) At the control box end, connect the 14 pin connectors
a) Drill the required holes in the mounting surface, of the cable to the mating receptacle on the bottom of
partially install 1/4-20 screws. the control box.
b) Mount the box. e) At the control box current sensor, slip the cover box
up off the sensor and connect the electrode cable(s)
c) Tighten the screws. to the top bolt connection.
LN-10
Electrode Routing a) Loosen the clamping collar screw using a 3/16"

Allen wrench. The clamping collar screw is
The electrode supply may be either from reels, Readi- accessed from the bottom of the feedplate. It is
Reels, spools, or bulk packaged drums or reels. the screw which is perpendicular to the feeding
Observe the following precautions: direction.
a) The electrode must be routed to the wire drive b) Loosen the retaining screw, which is also
unit so that the bends in the wire are at a mini- accessed from bottom of feeder, using a 3/16"
mum, and also that the force required to pull the Allen wrench. Continue to loosen the screw
wire from the reel into the wire drive unit is kept until the feedplate can be easily pulled off of the
at a minimum. wire feeder.
b) The electrode is "hot" when the gun trigger is 3) Loosen, but do not remove, the screw on the lower
pressed and must be insulated from the boom right face of the feedplate with a 3/16" Allen
and structure. wrench.
c) If more than one wire feed unit shares the same 4) Remove the screw on the left face of the feedplate.
boom and are not sharing the some power If changing from high speed (larger gear) to low
source output stud, their wire and reels must be speed (smaller gear), line the lower hole on the left
insulated from each other as well as insulated face of the feedplate with the threads on the
from their mounting structure. clamping collar. Line the upper hole with the
threads to install larger gear for high speed feeder.
WIRE DRIVE SPEED RANGE If feedplate does not rotate to allow holes to line
SELECTION
up, further loosen the screw on right face of feed-
plate.
The rated speed and wire size range for each wire 5) Install gear onto output shaft and secure with flat
drive head is shown in the SPECIFICATIONS in the washer, lock washer, and Phillips head screw
front of this section. which were previously removed.
Control Speed Range Setting 6) Tighten the screw on lower right face of feedplate.
The speed range is set up to match the wire feed 7) Re-attach feedplate to wire feeder if removed in
head connected to the LN-10 control by properly set- Step 2.
ting the switch (S1) code on the control board inside
the control box. See OPERATION “Setting the DIP 8) Feedplate will be rotated out-of-position due to the
Switches” for setting instructions. gear change. To re-adjust angle of feedplate:
10 Series Wire Drive Ratio Selection a) Loosen the clamping collar using a 3/16" Allen
wrench. The clamping collar screw is accessed
The 10 Series type drives include two external gear from the bottom of the feedplate. It is the screw
sizes; a 1" dia. gear and a 1-1/2" dia. gear. The small- which is perpendicular to the feeding direction.
er gear provides the low speed range ratio, and the
larger gear provides the high speed range ratio per b) Rotate feedplate to the desired angle and tight-
the SPECIFICATIONS in the front of this section. en clamping collar screw.
The following procedure is for changing ratio of the 10 9) Make sure to properly set the switch (S2) code on
Series wire drive: the control board inside the control box for the
new gear size installed. See OPERATION “Setting
1) Pull open the Pressure Door. the DIP Switch” for setting instructions.
2) Remove the Phillips head screw retaining the pin-

ion gear to be changed and remove the gear. If the
gear is not easily accessible or difficult to remove,
remove the feedplate from the gearbox. To remove
feedplate:
LN-10
WIRE FEED DRIVE ROLL KITS 3) Remove clamping screw & clamping collar from
the drive shaft closest to the incoming side of the
NOTE: The maximum rated solid and cored wire feeder.
sizes for each wire drive head and selected
drive ratio is shown on the SPECIFICATIONS 4) Install drive roll onto keyed shaft. (Do not exceed
in the front of this section. the maximum wire size rating of the wire drive.)
Replace collar and tighten clamping screw.
The electrode sizes that can be fed with each roll and 5) Back out the set screw for the middle guide tube.
guide tube are stenciled on each part. Check the kit Install the middle guide tube and slide it up against
for proper components. the drive roll. DO NOT TIGHTEN THE MIDDLE
GUIDE AT THIS TIME.
Synergic 7F Wire Drives (K679) use 4-Roll drive roll
kits with 2 driven rolls, per Table C.1 in ACCES- 6) Install the outgoing drive roll following the same
SORIES. These kits are common with those used for procedure as steps 3 & 4.
the 4-Roll LN-7 GMA and LN-9 GMA Lincoln Wire
Feeders, but are not common with those used with the 7) Center the middle guide between the two drive
10 Series wire drive units. Installation instructions are rolls and tighten in place.
included with the kits.
8) Back out the screws for the incoming and outgoing
10 Series Wire Drives use 4-Roll drive roll kits with 4 guide tubes.
driven rolls, per Table C.1 in ACCESSORIES.
9) Install the longer guide tube in the rear hole near
the incoming drive roll. Slide the tube in until it
PROCEDURE TO INSTALL DRIVE
almost touches the roll. Tighten in place.
ROLL AND WIRE GUIDES 10) Install the remaining guide tube in the front hole.
Be certain that the proper plastic insert is used.
WARNING Fine wire chisel point tube must have largest
radius next to drive roll. Tighten in place.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
11) Re-latch both quick release levers.
• When inching with gun trigger, electrode and
drive mechanism are “hot” to work and 12) To start new electrode, straighten the first 6"
ground and could remain energized several (150mm) and cut off the first 1" (25 mm). Insert
seconds after the gun trigger is released. free end through the incoming tube. Press gun
• Turn OFF input power at welding power trigger and push wire into the drive roll.
source before installation or changing
drive roll and/or guide tubes.
• Welding power source must be connected
TO SET IDLE ROLL PRESSURE, see “Idle Roll
to system ground per the National Pressure Setting” in OPERATION.
Electrical Code or any applicable local
codes. 10 Series Wire Drive Roll Kit Installation
(KP1505 and KP1507)
• Only qualified personnel should
perform this installation.
1) Turn OFF Welding Power Source.

Observe all additional Safety Guidelines detailed
throughout this manual. 2) Pull open Pressure Door to expose rolls and wire
guides.
Synergic 7F Wire Drive 4-Roll Kits (KP655 3) Remove Outer Wire Guide by turning knurled
and KP656) thumb screws to unscrew from Feedplate.
1) Turn OFF welding power source. 4) Remove drive rolls, if any are installed, by pulling
straight off shaft. Remove inner guide.
2) Release both quick release levers by sliding the
levers sideways into the open positions. 5) Insert inner Wire Guide, groove side out, over the
two locating pins in the feedplate.
LN-10
6) Install each drive roll by pushing over shaft until it Gun Cable Connection with Standard
butts up against locating shoulder on the drive roll Connection
shaft. (Do Not exceed maximum wire size rating of
the wire drive).
1. Check that the drive rolls and guide tubes are
7) Install Outer Wire Guide by sliding over locating proper for the electrode size and type being used.
pins and tightening in place. If necessary, change them per “Wire Drive Roll
Kits” in this section.
8) Engage upper drive rolls if they are in the “open”
position and close Pressure Door. 2. Lay the cable out straight. Insert the connector on
the welding conductor cable into the brass conduc-
TO SET IDLE ROLL PRESSURE, see “Idle Roll tor block on the front of the wire drive head. Make
Pressure Setting” in OPERATION. sure it is all the way in and tighten the hand clamp.
Keep this connection clean and bright. Connect the
GUN AND CABLE ASSEMBLIES
trigger control cable polarized plug into the mating
5 cavity receptacle on the front of the wire drive
WITH STANDARD CONNECTION unit.
The 10 Series Wire Drive Heads each require a 3. For GMA Gun Cables with separate gas fitting (10
K1500 Gun Adapter installed See “Gun Adapters” in Series Wire Drive using K1500-1 Gun Adapter),
ACCESSORIES section. The K1500-2 Gun Adapter connect the 3/16" I.D. gas hose from the wire drive
and Trigger Cable for Magnum 200-400 guns are fac- unit to the gun cable barbed fitting.
tory included with the LN-10.
GMAW Guns WITH FAST-MATE CONNECTION
(Requires K489-2 Fast Mate™ Adapter Kit used with
An expanding line of Magnum gun and cable assem- the K1500-1 Gun Adapter)
blies are available to allow welding with solid and
cored electrodes using the GMAW process See the
appropriate Magnum literature for descriptions of the
GMAW Guns
200 to 550 ampere air cooled gun and cables that are
available. Gun cable lengths range from 10 ft. (3.0 m) An expanding line of Magnum Fast-Mate™ air cooled
to 25 ft. (7.6 m) and feed electrode sizes .025" (0.6 and water cooled gun and cable assemblies are avail-
mm) to 3/32" (2.4 mm). The entire line of Magnum able to allow welding with solid and cored electrodes
Fast-Mate gun and cable assemblies can also be using the GMAW process. See the appropriate
used by installing a K489-2 Fast-Mate adapter kit. Magnum literature for descriptions of the 200 to 400
See “Gun and Cable Assemblies with Fast-Mate ampere air cooled gun and cables that are available
Connection” in this section for details. as well as the Magnum “Super Cool” 450 ampere
water cooled gun and cable. Gun cable lengths range
from 10 ft. (3.0 m) to 25 ft. (7.6 m) and feed electrode
Innershield Guns sizes .025" (0.6 mm) to 5/64" (20 mm).
K126 and K115 gun and cable assemblies are avail- An expanding line of Magnum X-Tractor gun and
able to allow welding with Innershield electrodes. Gun cable assemblies provides fume extraction capability
cable lengths range from 10 ft. (3.0 m) to 15 ft. (4.5 m) for welding with solid and cored electrodes using the
The 350 ampere K126 will feed electrode sizes .062 GMAW process. See the appropriate Magnum litera-
(1.6 mm) to 3/32" (2.4 mm). The 450 ampere K115 ture for descriptions of the 250 to 400 ampere air
will feed 5/64" (2.0 mm) to 3/32" (2.4 mm) electrode. cooled gun and cables that are available. Gun cable
lengths range from 10 ft. (3.0 m) to 15 ft. (4.5 m) and
Three smoke extraction gun and cable assemblies are feed electrode sizes .035" (0.9 mm) to 1/16" (1.6 mm).
available, 250 ampere K309, 350 ampere K206 and These guns require the use of either the K173-1 or
the 500 ampere K289. All gun cable lengths are 15 ft. K184* vacuum units.
(4.5 m). These guns will feed electrode sizes .062"
(1.6 mm) to 3/32" (2.4 mm) and require the use of the *Requires S14927-8 connector hose and an S20591
K184 vacuum unit for use with the LN-10. hose adapter.
LN-10
Gun Cable Connection with Fast-Mate GMAW Shielding Gas

Connection
1. Check that the drive rolls, feeder guide tubes and WARNING
gun connector guide tube are appropriate for the CYLINDER may explode if damaged.
electrode size being used. If necessary, change • Keep cylinder upright and chained to
them per “Wire Drive Roll Kits” in this section. support.
• Keep cylinder away from areas where
2. Connect gun to gun connector making sure all pins it may be damaged.
and gas tube line up with appropriate holes in con- • Never lift welder with cylinder attached.
nector. Tighten gun by turning large nut on gun • Never allow welding electrode to touch cylinder.
cable clockwise. • Keep cylinder away from welding or other live elec-
trical circuits.
10 SERIES WIRE DRIVE WATER BUILDUP OF SHIELDING GAS may
CONNECTIONS (FOR WATER
harm health or kill.
• Shut off shielding gas supply when not
COOLED GUNS) in use.
10 Series Wire Drive: must have a K590-4 Water SEE AMERICAN NATIONAL STANDARD Z-49.1,
Connection Kit installed for water cooled guns. (See “SAFETY IN WELDING AND CUTTING” PUBLISHED
ACCESSORIES). BY THE AMERICAN WELDING SOCIETY.
------------------------------------------------------------------------
Using male quick-connect fittings, connect the water
Customer must provide a cylinder of shielding gas, a
hoses to the coolant inlet and outlet on the back of the
pressure regulator, a flow control valve, and a hose
wire drive. Connect the other ends of these hoses to
from the flow valve to the gas inlet fitting of the wire
the appropriate ports on the water cooling units.
drive unit.
In the event the water line fittings on your water
Connect a supply hose from the gas cylinder flow
cooled gun are incompatible with the female quick
valve outlet to the 5/8-18 female inert gas fitting on the
connects on the front of the wire drive, male quick-
back panel of the wire drive or, if used, on the inlet of
connects (L.E. Part No. S19663) are provided in the
the Gas Guard regulator. (See Below).
Kit for installation on 3/16" (5 mm) I.D. hose
(Customer to provide appropriate clamps). The feeder
Gas Guard Regulator - The Gas Guard Regulator is
connectors self seal when disconnected.
an optional accessory (K659-1) on these models.
Install the 5/8-18 male outlet of the regulator to the

Synergic 7F Wire Drive (K679) :Must have a 5/8-18 female gas inlet on the back panel of the wire
K682-2 Water Connection Kit installed. (See ACCES- drive. Secure fitting with flow adjuster key at top.
SORIES). Attach gas supply to 5/8-18 female inlet of regulator
per instructions above.
Using hose clamps provided with the K682-2 kit, con-
nect appropriate water hoses to the coolant inlet and
outlet fittings on the back of the K682-2 Kit. Connect
the other ends of these hoses to the appropriate ports
on the water cooling units.
In the event the water line fittings on your water

cooled gun are incompatible with the female quick
connects on the front of the K682-2 Kit male quick-
connects are provided with the kit for installation on
3/16 (5 mm) I.D. hose (Customer to provide appropri-
ate clamps). The feeder connectors self seal when
disconnected.
LN-10
ELECTRICAL INSTALLATION Current Copper Work Cable Size, AWG

60% Duty
WARNING
Cycle Up to 100 ft Length (30m)
400 Amps 00 (67 mm2)
• Do not touch electrically live parts such
500 Amps 000 (85 mm2)
drive mechanism are “hot” to work and 600 Amps 000 (85 mm2)
ground and could remain energized several
seconds after the gun trigger is released.
• Turn OFF input power at welding power
source before installation or changing
drive roll and/or guide tubes.
to system ground per the National
codes.
perform this installation.
Observe all additional Safety Guidelines detailed throughout this manual.
Input Cable: LN-10 Control to Power

Source
K1501-10 (Control Cable only)

Consists of a 9-conductor control cable with 14-pin
control cable plug, without electrode cable, and is
available in a length of 10 ft. (3 m).
With input power disconnected from the power

source, install the input cable per the following:
1) Connect the end of the control cable with the 14-

pin cable plug to the mating receptacle on the
power source.
2) Connect the electrode lead to the power source

output terminal of the desired polarity.
3) Connect the 9-socket plug of the control cable to
the mating receptacle on the bottom of the LN-10
control box.
4) Slip the current sensor cover off enough to expose

the input connector stud. Connect the electrode
cable from the power source to this stud with the
nut provided, then reclose the current sensor
cover.
Work Cable
Connect a work lead of sufficient size and length (per

the following table) between the proper output termi-
nal on the power source and the work. Be sure the
connection to the work makes tight metal-to-metal
electrical contact.
LN-10
OPTIONAL FEATURES
INSTALLATION When installed and properly configured, the K1561-1
Robotics Interface Module allows complete control of
the welding process from the robot controller.
Dual Procedure Switch Options
The Lincoln Electric Companyʼs Automation Center
K683-1 Dual Procedure Switch (One per gun) - should be contacted for questions regarding installa-
Requires K686-2 Adapter for LN-10. Kit includes gun tion or operation of the Robotics Interface Module.
switch, and mountings for Lincoln Innershield and
Magnum guns, with 15 ft. (4.5 m) control cable and 3- All other options, see ACCESSORIES section, are
pin plug. K686-2 Adapter permits 3-pin plug and 5-pin shipped with installation instructions.
gun trigger plug to be connected to LN-10 5-pin
Trigger/Dual Procedure receptacle.
BOOM AND BENCH CONVERSIONS
Connect the 5-pin plug of the K686-2 Adapter to the
LN-10 Wire Feeder Trigger/Dual Procedure 5-socket The modular design of these feeders allows them to
receptacle. be converted from bench to boom models or vise
versa. Some additional parts are required to make this
The 3-pin plug of the K683-1 Dual Procedure switch conversion.
connects to the 3-socket receptacle of the Adapter,
and the 5-pin plug of the welding un connects to the 5- Materials Required for bench to boom
socket receptacle of the Adapter. conversion:
S13100-197 Plug and Lead assembly, allows a con-
K683-3 Dual Procedure Switch Kit includes gun
trol cable to connect from control box to the wire drive.
Magnum guns, with 15 ft. (4.5m) control cable and 5-
G2868 Mounting Bracket, allows reed switch to be
pin plug with two leads to connect to gun trigger.
relocated to control box.
Connect the 5-pin plug of the K683-3 Dual procedure
K1498-16 AND K1498-25 Control Box to Wire Drive,
Switch to the LN-10 Wire Feeder Trigger/Dual
Control cable and power cable from control box to
Procedure 5-socket receptacle.
wire drive.
The two lead plug cord extending out of the 5-pin plug
of the Dual Procedure switch is to be connected to the Materials Required for boom to bench
two trigger leads of the welding gun per the instruc- conversion:
tions shipped with the kit. L10286-1 Wire Reel Stand, for LN-10 or STT-10,
mount the reed switch onto the reel stand.
K1449-1 Dual Procedure Remote Control
Provides remote rotating knob encoder control of Wire S22777 Control Box Support Bracket, to mount the
Feed Speed and Voltage, along with a dual procedure control box onto the wire drive.
selector switch, when the remote control is connected
and REMOTE is selected by the LN-10 Procedure S13100-198 Plug and Lead Assembly, electrical con-
key. The LN-10 A or B procedure light will also be on nection between control box and wire drive.
to indicate which procedure is selected by the remote
control.
The 4-pin plug of the remote control connects to the

mating receptacle on the bottom of the LN-10 Control
box.
The K1450-”L” Extension cable is used to extend the

16 ft (5m) cable attached to the remote control.
Lengths “L” are available to match the Length of the
control to boom mount wire drive cable being used.
K1561-1 Robotics Interface Module - The module
plugs directly into the LN-10 control board and pro-
vides an interface to a properly equipped Fanuc robot.
LN-10
B-1 OPERATION B-1
OPERATING INSTRUCTIONS 1. Instead of displaying a preset value in volts, the top

Safety Precautions display will show a number from "0.00" to "10.00" in
increments of 0.02. The number can be used for
WARNING setting run-in "voltage" as well as "weld preset volt-
age". When the trigger is closed or while welding,
ELECTRIC SHOCK can kill. the top display will display actual arc voltage.
• Do not touch electrically live parts such The voltage displayed while welding can be used to
determine the arc voltage to be expected for a given
• Unless using cold feed feature when inch-
ing with gun trigger, electrode and drive mech- number setting. Actual arc voltage display will still
anism are “hot” to work and ground and could flash for 5 seconds after a weld has been completed.
remain energized several seconds after the
gun trigger is released. 2. If a loss of arc voltage occurs, wire will NOT stop
• Turn OFF input power at welding power feeding. The Loss of Voltage Sense Shutdown fea-
source before Control switch setup or
changing drive roll and/or guide tubes. ture is disabled to permit the use of the LN-10 with
• Welding power source must be connected power source connections that do not connect the
to system ground per the National work voltage back to the LN-10 through the input
Electrical Code or any applicable local power cable. The actual weld voltage while welding
codes. will NOT be shown on the top display if the work
• Only qualified personnel should voltage is not available to the LN-10 through the
operate this Equipment.
input power cable.

throughout this manual. Setup DIP Switch Access
Duty Cycle
The LN-10 models are rated at 60% duty cycle * for a 1) Shut off the input power to the LN-10 control by
maximum current of 600 amps. turning off the power at the welding power source it
* Based on a 10 minute time period (6 minutes on, and 4 minutes off).
LN-10 CONTROL DIP SWITCH WARNING

SETUP is connected to.
Have qualified personnel do the set up and
maintenance work. Turn the input power off at
Initial set up of the LN-10 control for the system com- the power source before working inside the wire
ponents being used and for general operator prefer- feeder.
ences is done using a pair of 8-pole DIP switches -----------------------------------------------------------------------
located inside the LN-10 control box. 2) Remove the two screws on the top of the LN-10
control box door and swing the door down to open.
"Other: Power Source Independent" power
source selection dip switch setting: 3) Locate the two 8-pole DIP switches, near the top
left corner of the LN-10 Control P.C. board, labeled
The LN-10 is designed to work with the following S1 and S2.
Lincoln Electric power sources: CV250, CV300-I,
CV300, CV400-I, CV400, CV500-I, CV655, DC250, NOTE: Switch settings are only programmed during
DC400, DC600, DC650 PRO, DC1000, Pulse Power input power-up restoration.
500 (non-pulse CV modes only), the V300 PRO,
V350 PRO, and the DC655. To use the LN-10 with
other power sources, the "Other: Power Source
Independent" power source selection dip switch set-
ting (S1 switches 1-4 in the OFF position) may be
used. All LN-10 features operate as described else-
where in this manual except for the following differ-
ences:
LN-10
B-2 OPERATION B-2
For K679-1 (Single Head Boom) with 50-770 IPM
Setting the DIP Switches (1.27-19.5 m/m) Low Speed Ratio set S1 DIP Switch
as follows:
The DIP switches are each labeled with an “ON”
arrow showing the on direction for each of the 8 indi- Pwr Sources Head
vidual switches in each DIP switch (S1 and S2). The ON 1 2 3 4 5 6 7 8 S1

functions of these switches are also labeled and set
as described below: S1
Pwr Sources Head For K679-2 (Single Head Boom) with 80-1200 IPM
(2.00-30.5 m/m) High Speed Ratio set S1 DIP Switch
M 4 S R + -
ON S1 ON S2
as follows:
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
S1 S2
Pwr Sources Head
Wire Drive Head Selection

ON 1 2 3 4 5 6 7 8 S1
S1
The LN-10 control is set up for proper presettable wire Note: The K679-1 and -2 require the K1562-1 control box.
feed speed by setting S1 DIP switches (5 to 8) as
appropriate per the following examples for the head Welding Power Source Selection
specification and 10 Series wire drive external gear
selection being used: The LN-10 Control is set up for proper presettable
weld voltage control by setting S1 DIP switches (1 to
4) as appropriate per the following information for the
For K1563-1,-3 or K1564-Series (LN-10 Boom) or welding power source being used:
K1559-1 (LN-10 Bench) with 35-500 IPM (0.89-12.7
m/m) Low Speed Ratio set S1 DIP Switch as follows:
Pwr Sources Head CV-250/CV 300-I:
ON 1 2 3 4 5 6 7 8 S1
Pwr Sources
S1 S1
ON
For K1563-1,-3 or K1564-Series (LN-10 Boom) or
1 2 3 4 5 6 7 8
K1559-1 (LN-10 Bench) with 50-750 IPM (1.25-19.0 S1
m/m) High Speed Ratio set S1 DIP Switch as fol-

lows: (initial factory setting)
Pwr Sources Head
CV-300/CV 400-I:
ON 1 2 3 4 5 6 7 8 S1 Pwr Sources
S1 ON 1 2 3 4 5 6 7 8 S1
S1
For K1563-2,-4 (LN-10 Boom) or K1559-2 (LN-10

Bench) with 55-825 IPM (1.40-21.0 m/m) Low CV-400/CV 500-I:
Speed Ratio set S1 DIP Switch as follows: Pwr Sources
Pwr Sources Head ON 1 2 3 4 5 6 7 8 S1
ON 1 2 3 4 5 6 7 8 S1
S1
S1
For K1563-2,-4 (LN-10 Boom) or K1559-2 (LN-10 CV-655: (initial factory setting)
Bench) with 80-1250 IPM (2.00-31.8 m/m) High Pwr Sources
Speed Ratio set S1 DIP Switch as follows: ON 1 2 3 4 5 6 7 8 S1
Pwr Sources Head
S1
ON 1 2 3 4 5 6 7 8 S1
S1 V350-PRO And V450-PRO:

Pwr Sources
ON 1 2 3 4 5 6 7 8 S1
S1
LN-10
B-3 OPERATION B-3
DC-250: *
Metric/English Wire Feed Speed Display Selection
The LN-10 Control is set up for Wire Feed Speed dis-
Pwr Sources
ON 1 2 3 4 5 6 7 8 S1
play in Metric units (m/min.) or English units (IPM) by
S1
setting S2 DIP Switch 1 (Labeled “M”):
S2 switch 1 OFF = IPM (as shipped)

DC-400:
Pwr Sources
M 4 S R + -
ON S1 S2
1 2 3 4 5 6 7 8 ON 1 2 3 4 5 6 7 8
S1 S2
DC-600:
S2 switch 1 ON = m/min
Pwr Sources
ON S1
1 2 3 4 5 6 7 8 M 4 S R + -
ON 1 2 3 4 5 6 7 8 S2
S1
S2
DC-650 PRO:
Pwr Sources 4-Step Trigger Mode Operation Selection
ON S1 The LN-10 Control is set up for 4-Step Trigger mode
operation with or without weld current interlock by set-
1 2 3 4 5 6 7 8
S1 ting S2 DIP switch 2 (Labeled “4”).

DC-1000: *
When 4-Step trigger mode is selected on the LN-10
Pwr Sources keypad (See Keypad and Display Operation in this
section) S2 DIP switch setting determines the 4-step
trigger operation:
ON 1 2 3 4 5 6 7 8 S1
S1
S2 switch 2 OFF = 4-Step with current interlock
Pulse Power 500: * operation: (As shipped)
Pwr Sources M 4 S R + -
ON 1 2 3 4 5 6 7 8 S2
ON 1 2 3 4 5 6 7 8 S1
S2
S1
V300 PRO: 1) Closing Trigger initiates gas preflow time followed

by Run-in speed and strike voltage until arc strike
initiates welding.
Pwr Sources
ON 1 2 3 4 5 6 7 8 S1
2) Opening Trigger after welding arc is established

continues welding with weld current interlock.
S1
10.0 TO 45.0 VOLT LINEAR PRESET (Breaking arc stops the feeder operation).
(FOR POWER SOURCES WITH LINEAR VOLTAGE
CONTROL PROTOCOL) 3) Reclosing Trigger continues welding but shuts off
current interlock function.
Pwr Sources
ON 1 2 3 4 5 6 7 8 S1 4) Reopening Trigger stops wire feed and initiates

burnback time, then gas postflow time.
S1
0.0 TO 10.0 LINEAR PRESET:

Pwr Sources
ON 1 2 3 4 5 6 7 8 S1
S1
* Requires optional K1520-1 115V/42V Transformer

Kit.
LN-10
B-4 OPERATION B-4
S2 switch 2 ON = 4-Step without current interlock Robotics Mode Selection
operation:
The LN-10 control is set up for Robotics Mode by set-
M 4 S R + - ting the S2 DIP Switch 4 (Labeled “R”). For Robotics
ON 1 2 3 4 5 6 7 8 S2
Interface Mode to operate, a K1561-1 Robotics
S2
Interface Module must be installed.
S2 switch 4 ON = Robotics mode ON

1) Closing Trigger initiates gas flow. M 4 S R + -
ON S2
2) Opening Trigger initiates gas preflow timer fol-
1 2 3 4 5 6 7 8
lowed by Run-in speed and strike voltage until arc S2
strike initiates welding. (Trigger is released before

arc is struck, but once established breaking arc
stops the feeder operation). S2 switch 4 OFF = Robotics mode OFF (As shipped)
3) Reclosing Trigger stops wire feed and initiates M 4 S R + -

burnback time, then gas postflow time. ON 1 2 3 4 5 6 7 8 S2
4) Reopening Trigger stops gas flow if, or when, post- S2
flow time is over.
Maximum Limits Setting Mode Selection
The LN-10 control is set up for allowing a maximum

Security Mode Selection weld WFS and arc voltage setting for each procedure
by setting S2 DIP Switch 5 (Labeled “+”)
The LN-10 Control is set up for Security Mode (See
“Security Mode” in this section) by setting S2 DIP S2 switch 5 ON = Max. Limits Setting mode ON
Switch 3 (Labeled “S”):
M 4 S R + -
S2 switch 3 ON = Security mode ON ON 1 2 3 4 5 6 7 8 S2
M 4 S R + - S2
ON 1 2 3 4 5 6 7 8 S2
S2
When Maximum Limits Setting mode is selected, all keys
except the procedure key are disabled. Welding is not
S2 switch 3 OFF = Security mode OFF (as shipped) allowed while in this mode. The mode is used for maxi-
mum limits setup only. See “Limits Setting Mode” in this
section for the correct procedure for setting the WFS and
M 4 S R + - voltage limits.
ON 1 2 3 4 5 6 7 8 S2
S2 switch 5 OFF = Maximum Limits Setting mode
OFF (As shipped)
S2
M 4 S R + -
ON 1 2 3 4 5 6 7 8 S2
S2
LN-10
B-5 OPERATION B-5
Minimum Limits Setting Mode Selection
The LN-10 control is set up for allowing a minimum weld

WFS and arc voltage setting for each procedure by set-
ting S2 DIP Switch 6 (Labeled “-”).
S2 switch 6 ON - Minimum Limits Setting mode ON
M 4 S R + -
ON 1 2 3 4 5 6 7 8 S2
S2
When Minimum Limits Setting mode is selected, all keys

except the procedure key are disabled. Welding is not
allowed while in this mode. The mode is used for mini-
mum limits setup only. See “Limits Setting Mode” in this
section for the correct procedure for setting the WFS and
voltage limits.
S2 switch 6 OFF = Minimum Limits Setting mode OFF

(As shipped)
M 4 S R + -
ON 1 2 3 4 5 6 7 8 S2
S2
LN-10
B-6 OPERATION B-6
KEYPAD AND DISPLAY OPERATION Power-Down Save
Power to the LN-10 is supplied and controlled from

the power source. The LN-10 automatically senses
LINCOLN R
the loss of power when the power source is turned off.

Dual procedure settings, including; trigger mode, cold
COLD FEED COLD FEED
V
FORWARD REVERSE GAS PURGE
feed speed, Run-in and weld speed and voltage,

timers and acceleration are automatically saved for
WFS
each feeder when power is removed. This feature

A REMOTE B
does not require batteries and when power is restored

PROCEDURE
it will automatically return all settings to the state they

were in when power was removed. The operator may
V VOLTS
overwrite any or all of these settings following power

COLD FEED
TRIGGER
up recall.
2-STEP STD
4-STEP LOCK
SPOT
1 PREFLOW RUN-IN
VOLTS / WFS
SPOT
Operation Keys
BURNBACK
WIRE FEED SPEED
2 POSTFLOW
Procedure Lights - Indicate which

procedure (A or B) is selected for the
TIMER CONTROL
selected feeder. The Procedure select

A REMOTE B
Keypad and Display Description key selects A or B, or if REMOTE Light

THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO U.S.A. G3161
is selected, the procedure selection

PROCEDURE
Keypad - Seven key, membrane type with "snap" tac- light is controlled by connection of an
tile feel and embossed domes. Long life design. optional Dual Procedure gun switch
Spatter resistant surface. (K683-1, -3) or Dual Procedure
Remote Control (K1449-1).
Displays - Two digital LED displays with .56" (14.2

mm) character height. Top (3-1/2 digit) displays Cold Feed Keys - energize
Preset and Actual (while welding) arc voltage in volts the wire feeder but not the
COLD FEED COLD FEED
power source or gas sole-

FORWARD REVERSE
with (+) or (-) polarity indicators, and also displays all

timers in seconds. Bottom (4 digit) displays preset noid valve. Cold Feed
wire feed speed in IPM, or m/m, and acceleration Forward speed is factory
selection. set at 200 IPM, but is adjustable with WFS encoder
knob and displayed on WFS display (with ”Cld” shown
on the Voltage display) only while pressing Cold Feed
Indicator Lights - Extra bright red LEDs for viewing Forward, and the last speed set is stored in memory
at almost any angle. Always indicate the feeder and for the next cold feeding, unless changed in Cold
procedure selected, trigger mode being used and Feed trigger mode (see following section). Cold Feed
function or timer being displayed. Reverse retracts wire at a fixed 80 IPM speed which is
not adjustable.
Rotating Encoders - Knob controls increase or

decrease settings of volts and wire feed speed. (ini- Gas Purge key - energizes the gas
tially factory set to minimum) Alternately, the top solenoid valve but not the wire feeder or
GAS PURGE
encoder adjusts timer settings and bottom selects power source.

acceleration settings when selected for these parame-
ters to be displayed.
LN-10
B-7 OPERATION B-7
Trigger Mode Selection Display Control Keys
Trigger Mode Select key Timer Select key - enables operator to

- enables operator to choose burnback, spot or gas timers, as
TIMER
choose mode of operation indicated by the appropriate light.

COLD FEED
shown by the indicator

TRIGGER
Pressing the key causes lights to

2-STEP STD
lights. Pressing key caus- sequence (top to bottom, then all off) starting from the
4-STEP LOCK
es mode lights to current indicated selection.

SPOT
sequence (top to bottom) starting from the current

indicated selection. When a timer is selected the Voltage display shows
the time setting in seconds, as indicated by “SEC” dis-
Top Light - Indicates gun trigger has been selected to played on the speed display. The times are set using
perform the Cold Feed Forward function in exactly the the Voltage encoder knob.
same manner as Cold Feed Forward key (See
Operation Keys - Cold Feed Keys) with the same Top Light - indicates preflow time
memory stored adjustable speed setting, and “Cld” is being displayed, set 0.0 to 2.5
shown on the Voltage display. seconds (0.2 sec as shipped). This
1 PREFLOW
is the time the shielding gas flows

Second Light - indicates 2-step (standard) trigger before the wire feed and power
SPOT
mode. source are activated.

BURNBACK
1. Trigger closure energizes the solenoid valve, Second Light - indicates spot time is being displayed,
2 POSTFLOW
then the wire feeder and the power source set 0.0 (as shipped) to 199.9 seconds.
after Preflow time.
Third Light - indicates burnback time is being dis-
2. Releasing the trigger turns off the wire feeder, played, set 0.00 (as shipped) to 0.25 seconds. This is
then power source after burnback time and the time the arc power is delayed at the stop of the
then the gas solenoid valve after Postflow time. weld, and should be set to the lowest time required to
prevent the wire sticking in the weld.
Third Light - indicates 4-step (lock) trigger mode.
This mode may be selected to include or exclude weld Bottom Light - indicates postflow time is being dis-
current interlock. (See “4-Step Trigger Mode played, set 0.0 to 10.0 seconds (0.5 sec as shipped).
Operation Selection” in this section for 4 step Trigger
Mode operation) This is the
time the shielding gas flows after the wire feed and
Bottom Light - indicates Spot Weld Mode, which will power source are deactivated.
only light if a spot time is set (See “Display Control
Keys” in this section). If set to 0.0 seconds, spot Pressing Timer Select Key again, or closing the gun
mode light selection will be skipped. Trigger closure trigger, shuts all timer lights off, indicating weld
energizes the gas solenoid valve, then wire feeder Voltage and Wire Feed Speed are again being dis-
and the power source. The spot timer starts when played, and set by the appropriate encoder knob.
current flows. The wire feeder and power source then
solenoid valve are all turned off when the spot on
timer times out even though the trigger is opened or is
still closed. Preflow/Postflow and burnback timers are
also functional in spot mode. (See “Display Control
Keys” in this section).
LN-10
B-8 OPERATION B-8
Control Select key - enables operator to Acceleration Selection

choose Run-In procedure as indicated by the To provide optimum starting of various
GAS PURGE
light turning on. When light is on, the settings of

CONTROL
processes and procedures, the wire feed

Run-In Wire Feed Speed and Voltage are dis- acceleration of the LN-10 can be set to five lev-
played. After Weld procedure is set, Run-in pro- els; 1 thru 5, for each feeder and procedure. 1
cedure should be set to optimize arc starting. is the slowest acceleration and 5 is the fastest.
CONTROL
(Factory set to 4.)

Speed encoder knob can adjust run-in
speed between min. rated speed and up to To change acceleration hold the Gas Purge Key closed, then
the procedure Weld speed setting. Run-in press the Control key. The top (Voltage) display shows “Acc”
RUN-IN
speed setting can not exceed Weld speed indicating acceleration setting, 1 thru 5, is displayed on the bot-
VOLTS / WFS
setting. Run-in speed setting of 100 IPM or less is recommend- tom (Speed) display. Use the speed encoder knob to change
ed for optimum starting. Factory setting is near min. rated setting from 1 thru 5.
speed.
To exit this function, and enter the acceleration setting into the
If set below minimum rated speed “- -” will show on the WFS procedure memory, press both keys again or close the trigger.
display, indicating Run-in speed is set to match weld speed set-
ting.
Security Mode
The Run-in (strike) voltage can be set above or below the Weld
Security mode is used to capture timer, acceleration, and control
voltage setting up to a max of 60 V. If set below a min of 10 V,
selections and settings, then to disable these selections until
the Run-In (strike) voltage display shows “---”, indicating the
security mode is deactivated. Encoder knob setting changes of
Run-In Voltage is set to match the weld voltage setting. Also,
cold feed, weld speed and weld voltage are not disabled.
the difference between Run-in voltage and Weld voltage set-
tings is maintained automatically if the Weld voltage setting is
Security mode is activated, or deactivated, by shutting off the
changed, so the run-in voltage encoder knob does not need to
input power to the LN-10 with all Timer and Control settings as
be changed to follow the Weld voltage setting.
desired for both procedures for both Feeders. Then setting S2
DIP switch 3 inside the LN-10 Control Box ON or OFF and restor-
When trigger is closed (and preflow time is over) the wire feeds
ing input power (See “Setting DIP Switches” in this section).
at Run-In speed and volts until the welding arc strikes, which
causes the feed speed and volts to change to Weld settings.
When activated, the Timer and Control selections no longer light,
but function with the captured settings. All other keys and
If the arc does not strike within about 2 seconds, the Run-In
encoder knob controls function normally.
speed automatically changes to Weld speed to permit “Hot”
feeding at higher speed setting for loading wire.
Pressing control key again, or closing the gun trigger, shuts off
light indicating knob settings and displays are returned to Weld
Voltage and Wire Feed Speed.
Digital “Memory” Voltmeter
When the welding gun trigger is activated, the top LN-10 display
reads actual welding voltage from 0.0 to 60.0 VDC with auto-
matic polarity indication for positive (+) or negative (-) electrode.
If actual voltage drops below 8.0 volts for over 0.8 sec when the
trigger is closed, Loss of Voltage Sense Shutdown will occur.
See “Loss of Voltage Sense Shutdown” in this section.
The last welding voltage monitored at the end of the weld is dis-
played for 5 seconds after the weld has stopped, as indicated
by a 5 second “blinking” display. This allows checking actual
weld voltage after weld has stopped.
Any keypad or trigger operation will interrupt the 5 second

memory display.
LN-10
B-9 OPERATION B-9
Maximum and Minimum Limits Setting 8. Open the control box door.
Modes
9. Put DIP switch S2 switch 5 in the OFF position and
Limits setting modes are available for limiting the DIP switch S2 switch 6 in the ON position.
range for setting wire feed speed and voltage. The
limits can be set independently for each procedure. 10. Close the control box door.
The following steps should be followed for setting the
maximum and minimum limits: 11. Turn on the power at the power source.
1. Turn off the power at the power source. 12. Set the minimum WFS and voltage limits for pro-
cedure A and procedure B using the two encoder
2. Remove the two screws at the top of the LN-10 knobs and the procedure key. The minimum WFS
control box and open the control box door. limit can be set from the minimum speed of the
wire drive that is being used to the maximum limit
3. Put DIP switch S2 switch 5 in the ON position. that has been set for the selected procedure. The
minimum voltage limit can be set over the range of
4. Close the control box door. 10.0 to the maximum voltage limit that has been
set for the selected procedure. The minimum lim-
5. Turn on the power at the power source. its can be turned off independently for each proce-
dure by turning the encoder knobs counter clock-
6. Set the maximum WFS and voltage limits for pro- wise until the appropriate display (WFS or voltage
cedure A and procedure B using the two encoder reads “OFF” while the correct procedure light is
knobs and the procedure key. The maximum WFS lit. (The limits are set to “OFF” from the factory).
limit can be set for the entire range of the wire
drive that is being used. The maximum voltage 13. Turn off the power at the power source.
limit can be set over the range of 10.0 to 60.0 volts.
The maximum limits can be turned off indepen- 14. Open the control box door.
dently for each procedure by turning the encoder
knobs clockwise until the appropriate display (WFS 15. Put DIP switch S2 switch 6 in the OFF position.
or voltage) reads “OFF” while the correct proce-
dure light is lit. (The limits are set to “OFF” from 16. Close the control box door.
the factory.
17. Reinstall the two screws that had previously been
7. Turn off the power at the power source. removed in step 2.
LN-10
B-10 OPERATION B-10
DUAL PROCEDURE REMOTE WARNING

CONTROL (K1449-1) Check to be sure the Retaining Spring has fully
returned to the locking position and has SECURELY
When this option is connected to the LN-10 Control locked the Readi-Reel Cage in place. Retaining
Box receptacle, and the Procedure Key selects Spring must rest on the cage, not the welding elec-
“REMOTE” the front panel knob controls and proce- trode.
dure selection is transferred to the knob encoder con- ___________________________________________
trols and Procedure Selector Switch of the remote,
which function in the exact same manner. Remote 9) To remove Readi-Reel from Adapter, depress
knob encoders set Weld voltage and wire feed speed, retaining spring tab with thumb while pulling the
as well as Trigger Cold Feed Speed, but not Timers or Readi-Reel cage from the molded adapter with
Run-In. both hands. Do not remove adapter from spindle.
If using the optional K683-1, -3 Dual Procedure

Switch, for a wire drive, to select A or B along with the
(K1449-1) remote, both the front panel and remote
Procedure selector and switch must be set to
“REMOTE” and “Gun Switch” (center) positions.
The LN-10 Procedure lights indicate whether A or B is

remotely selected.
WIRE REEL LOADING - READI-REELS,

SPOOLS OR COILS
To Mount a 30 Lb. (14 kg) Readi-Reel Package
(Using the Molded Plastic K363-P Readi-Reel
Adapter:)
The Spindle should be located in the LOWER mounting hole. FIGURE B.1
1) Depress the Release Bar on the Retaining Collar To Mount 10 to 44 Lb. (4.5-20 kg) Spools
and remove it from the spindle. (12"/300 mm Diameter) or 14Lb.(6 Kg)
Innershield Coils:
2) Place the Adapter on the spindle.
The Spindle should be located in the LOWER mounting hole.
3) Re-install the Retaining Collar. Make sure that the
Release Bar “pops up” and that the collar retainers (For 8" (200 mm) spools, a K468 spindle adapter must
fully engage the retaining groove on the spindle. first be slipped onto spindle.)
4) Rotate the spindle and adapter so the retaining (For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil
spring is at the 12 o'clock position. Adapter must be used).
5) Position the Readi-Reel so that it will rotate in a 1) Depress the Release Bar on the Retaining Collar
direction when feeding so as to be de-reeled from and remove it from the spindle.
bottom of the coil.
2) Place the spool on the spindle making certain the
6) Set one of the Readi-Reel inside cage wires on the spindle brake pin enters one of the holes in the
slot in the retaining spring tab. back side of the spool. Be certain the wire comes
off the reel in a direction so as to de-reel from the
7) Lower the Readi-Reel to depress the retaining bottom of the coil.
spring and align the other inside cage wires with
the grooves in the molded adapter. 3) Re-install the Retaining Collar. Make sure that the
Release Bar “pops up” and that the collar retainers
8) Slide cage all the way onto the adapter until the fully engage the retaining groove on the spindle.
retaining spring "pops up" fully.
LN-10
B-11 OPERATION B-11
To Mount a 50-60 Lb. (22.7-27.2 kg) Coil: FEEDING ELECTRODE AND BRAKE
(Using K1504-1 Coil Reel) (For 50-60 lb Readi- ADJUSTMENT
Reels a K438 Readi-Reel Adapter must be used).
1) Turn the Reel or spool until the free end of the
The Spindle must be located in the UPPER mounting hole. electrode is accessible.
1) With the K1504-1 Coil Reel mounted on to the 2" 2) While tightly holding the electrode, cut off the bent
(51 mm) spindle (or with reel laying flat on the end and straighten the first 6" (150 mm). Cut off
floor) loosen the spinner nut and remove the reel the first 1" (25 mm). (If the electrode is not proper-
cover. (See Figure B.2). ly straightened, it may not feed or may jam causing
a "birdnest".)
2) Before cutting the tie wires, place the coil of elec-
trode on the reel so it unwinds from the bottom as 3) Insert the free end through the incoming guide
the reel rotates. tube.
3) Tighten the spinner nut against the reel cover as 4) Press the Cold Inch key or the Cold Feed Mode
much as possible by hand using the reel cover gun trigger and push the electrode into the drive
spokes for leverage. DO NOT hammer on the roll.
spinner nut arms.
4) Cut and remove only the tie wire holding the free
WARNING
end of the coil. Hook the free end around the rim When feeding with the gun trigger, unless “COLD
of the reel cover and secure it by wrapping it FEED” trigger mode is selected, the electrode and
around. Cut and remove the remaining tie wires. drive mechanism are always “HOT” to work and
ground and could remain “HOT” several seconds after
CAUTION the gun trigger is released.
___________________________________________
Always be sure the free end of the coil is securely
held while the tie wires are being cut and until the wire 5) Feed the electrode through the gun.
is feeding through the drive rolls. Failure to do this will
result in “backlashing” of the coil, which may tangle 6) Adjust the brake tension with the thumbscrew on
the wire. A tangled coil will not feed so it must either the spindle hub, until the reel turns freely but with
be untangled or discarded. little or no overrun when wire feeding is stopped.
___________________________________________ Do not overtighten.
5) Be sure the coil reel is engaged with the spindle
DRIVE ROLL PRESSURE SETTING
brake pin and the Release Bar on the Retaining
Collar “pops up” and that the collar retainers fully
engage the retaining groove on the spindle.
SPINNER NUT The LN-10 pressure is factory pre-set to about posi-
tion “2" as shown on the pressure indicator on the
COVER front of the feedplate door. This is an approximate
setting.
PLATE
The optimum drive roll pressure varies with type of

wire, surface condition, lubrication, and hardness.
SLOTS
CARDBOARD
Too much pressure could cause “birdnesting”, but too
little pressure could cause wire feed slippage with
COIL LINER
load and/or acceleration. The optimum drive roll set-

ting can be determined as follows:
COIL
TIE WIRE
SPRING
LOADED ARM
REEL
FIGURE B.2
LN-10
B-12 OPERATION B-12
1) Press end of gun against a solid object that is
4) Use Control Select and encoder knobs to set desired
electrically isolated from the welder output and
Weld feed speed and voltage then Run-in speed and
press the gun trigger for several seconds.
voltage to optimize arc starting. (Set for each proce-
dure if using front panel, remote control or optional
2) If the wire "birdnests", jams, or breaks at the drive
dual procedure switch.) (Refer to “Operation Keys”
roll, the drive roll pressure is too great. Back the
and “Display Control Keys” in this section)
pressure setting out 1/2 turn, run new wire through
gun, and repeat above steps.
5) Adjust the wire feed acceleration if desired, for
each feeder and procedure. (Refer to “Acceleration
3) If the only result is drive roll slippage, disengage
Selection” in this section)
the gun, pull the gun cable forward about 6" (150
mm). There should be a slight waviness in the
6) Use Timer Select and Voltage Encoder knob to set
exposed wire. If there is no waviness, the pres-
desired timers. (Refer to “Trigger Mode Selection”
sure is too low. Increase the pressure setting
in this section)
turn, reconnect the gun, tighten locking clamp and
repeat the above steps.
7) Feed the electrode through the gun and cable and
PROCEDURE FOR SETTING ANGLE

then cut the electrode within approximately .38"
(9.5 mm) of the end of the contact tip for solid wire
OF FEEDPLATE and within approximately .75" (19mm) of the exten-
sion guide for cored wire.
1) Loosen the clamping collar screw using a 3/16"
Allen wrench. The clamping collar screw is 8) Connect work cable to metal to be welded. Work
accessed from the bottom of the feedplate. It is cable must make good electrical contact to the
the screw which is perpendicular to the feeding work. The work must also be grounded as stated in
direction. "Arc Welding Safety Precautions".
2) Rotate feedplate to the desired angle and tighten WARNING

clamping collar screw. When using an Open Arc process,
it is necessary to use correct eye,
GAS GUARD REGULATOR SETTING head, and body protection.
NOTE: Gas supply pressure must be regulated to a
maximum of 80 psi(5.5 bar). ____________________________________
9) If used, be sure shielding gas valve is turned on.
1) With the gas supply shut off, the Gas Guard regu-
lator flow adjusting Key should be set to maximum 10) Position electrode over joint. End of electrode
(full clockwise) which is rated to be 60 SCFH (28 may be lightly touching the work.
l/min).
11) Lower welding helmet, close gun trigger, and start
2) Adjust gas supply flow rate for a level higher than welding. Hold the gun so the contact tip to work
will be required, then adjust Gas Guard flow distance gives the correct electrical stickout as
adjusting Key counterclockwise to the desired gas required for the procedure being used.
flow rate.
12) To stop welding, release the gun trigger and then
MAKING A WELD pull the gun away from the work after the arc goes
out and Postflow time, if used, is over.
1) Use only a Lincoln Electric recommended constant
voltage DC power source compatible with the LN- 13) If necessary to optimize arc starting, readjust wire
10 Wire Feeder. speed acceleration, (Refer to “Acceleration
Selection” in this section) and/or Run-In speed,
2) Properly connect the electrode and work leads for (Refer to “Display Control Keys” in this section).
the correct electrode polarity.
3) Use the Mode Selection key to set desired trigger

mode for each procedure. (Refer to “Trigger Mode
Selection” in this section)
LN-10
B-13 OPERATION B-13
WIRE REEL CHANGING WIRE FEED OVERLOAD PROTECTION

At the end of a coil, remove the last of the old elec- The LN-10 has solid-state overload protection of the
trode coil from the conductor cable by either pulling it wire drive motor. If the wire drive motor becomes
out at the nozzle end of the gun or by using the follow- overloaded for an extended period of time, the protec-
ing procedure: tion circuitry turns off the power source, wire feed and
gas solenoid, and then displays “H30” on the WFS
1) Cut the end of the electrode off at the gun end. Do display (with blank Voltage display). This indicates
not break it off by hand because this puts a slight the wire drive motor is overloaded and will remain
bend in the wire making it difficult to pull it back shut down for about 30 seconds before the unit will
through the nozzle. automatically reset. The “H30” display decrements
every second until it reaches “H00”. At that time, the
2) Disconnect the gun cable from the gun connector unit resets automatically and the previous displays will
on the LN-10 wire drive unit and lay the gun and return indicating the unit is ready to operate again.
cable out straight. Overloads can result from improper tip size, liner,
drive rolls, or guide tubes, obstructions or bends in the
3) Using pliers to grip the wire, pull it out of the cable gun cable, feeding wire that is larger than the rated
from the connector end. capacity of the feeder or any other factors that would
impede normal wire feeding. (See “Avoiding Wire
4) After the electrode has been removed, reconnect Feeding Problems” in the MAINTENANCE section).
the gun cable to the drive. Load a new reel of elec-
trode per the instructions in “Wire Reel Loading” in GROUNDING LEAD PROTECTOR
this section.
LOSS OF VOLTAGE SENSE SHUTDOWN

The frame of the LN-10 Control is grounded to the
frame of the power source by a lead in the control
cable. An overload protector prevents welding current
If the actual displayed voltage, when the trigger is from damaging this lead if the electrode circuit touch-
closed, drops below 8.0 volts for over 0.8 second it is es the wire feeder frame while the electrode is electri-
assumed the voltage feed back sensing circuit to the cally hot.
LN-10 is opened or faulty, so Loss of Voltage Sense
Shutdown occurs until the trigger is released. If such a grounding lead fault occurs, the WFS display
will show “GLP,” (with blank Voltage display) and the
This shutdown stops the motor, shuts off the gas flow trigger circuit will be disabled. To reset the circuit,
and disables the power source output to prevent the release the trigger, make sure that the electrode is not
LN-10 voltage control from driving the power source touching the wire feeder frame, and then either press
output too high due to loss of proper feedback sensing any key on the keypad or close the trigger. When the
via #21 (WORK) and #67 (ELECTRODE) sensing GLP circuit is reset, the “GLP” display is removed and
leads. the wire feeder is returned to normal operating mode.
LN-10
B-14 OPERATION B-14
EXPLANATION OF PROMPTING Er EEPROM error. Usually occurs at power-up.

AND ERROR MESSAGES
Indicates one or more of the recalled settings is out
of acceptable limits. Press any key to return to nor-
mal operation. Be sure to check all voltage, wire feed
speed, acceleration and timer settings before you
Display Prompt or Error proceed.
Acc Displayed on Voltage display, indicates WFS

display is showing acceleration setting, “1" to
“5" (See “Acceleration Selection” in this sec-
tion).
OFF Displayed on WFS and voltage displays; indi-

cates limits for WFS or voltage are off for the
displayed procedure. (See “Maximum and
Minimum Limits Setting Modes” in this sec-
tion).
SEC Displayed on WFS display, indicates Voltage

display is showing a Timer setting in sec-
onds. (See “Display Control Keys” in this
section)
GLP Displayed on WFS display, indicates that the

Grounding Lead Protector circuit was activat-
ed due to excessive current flow into the
wire feeder frame. When the GLP circuit is
activated the wire feeder is disabled (the trig-
ger output to the power source is opened up,
the motor is stopped, and the gas solenoid is
turned off). To resume normal operation,
release the trigger, make sure that the elec-
trode is not touching the wire feeder frame,
and then either press a key on the keypad or
close the trigger. (See “Grounding Lead
Protector” in this section)
Cld Displayed on Voltage display when Cold

Feed Forward or Cold Feed Reverse Key is
pressed, or Cold Feed Trigger mode is
selected. Indicates wire is fed “cold” (no
weld voltage) at the speed indicated on the
WFS display. (See “Operation Keys” and
“Trigger Mode Selection” in this section).
--- Displayed on Voltage or WFS displays with

RUN-IN selected, indicates setting will match
those set for Weld Voltage and Wire Feed
Speed (See “Display Control Keys” in this
section).
HXX Displayed on WFS display, indicates wire feed over-

load. XX indicates time remaining in seconds before
unit resets automatically. (See “Wire Feed Overload
Protection” in this section and “Avoiding Wire
Feeding Problems” in the MAINTENANCE section).
LN-10
C-1 ACCESSORIES C-1
TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS
Wire Size 4-Roll 4-Roll

DH Drive Single Drive
(4-Driven) (2-Driven)
Solid Steel Electrode
0.025” (0.6 mm) KP1505 - 030S KP655 - 025S
0.030” (0.8 mm) KP1505 - 030S KP655 - 030S
0.035” (0.9 mm) KP1505 - 035S KP655 - 035S
0.040” (1.0 mm) KP1505 - 040S KP655 - 035S
0.040” (1.0 mm) KP1505 - 045S KP655 - 035S
0.045” (1.2 mm) KP1505 - 045S KP655 - 052S
0.052” (1.4 mm) KP1505 - 052S KP655 - 052S
1/16” (1.6 mm) KP1505 - 1/16S KP655 - 1/16
5/64” (2.0 mm) KP1505-5/64 KP655 - 3/32
3/32” (2.4 mm) KP1505-3/32 ---------------
Cored Electrode
0.030 (0.8 mm) KP1505 - 035C ---------------
0.035” (0.9 mm) KP1505 - 035C KP655 - 035C
0.040” (1.0 mm) KP1505 - 045C KP655 - 035C
0.045” (1.2 mm) KP1505 - 045C KP655 - 052C
0.052” (1.4 mm) KP1505 - 052C KP655 - 052C
1/16” (1.6 mm) KP1505 - 1/16C KP655 - 1/16
0.068” - 0.072” (1.7 - 1.8 mm) KP1505 - 068 KP655 - 3/32
5/64” (2.0 mm) KP1505 - 5/64 KP655 - 3/32
3/32” (2.4 mm) KP1505 - 3/32 ---------------
7/64” Lincore Hard Facing (2.8mm) KP1505 - 7/64H ---------------
7/64” (2.8mm) KP1505 - 7/64 ---------------
.120” (3.0mm) KP1505 - 120 ---------------
Aluminum Electrode
0.035” (0.9 mm) KP1507 - 035A KP656 - 035A
0.040” (1.0 mm) KP1507 - 040A ---------------
3/64” (1.2 mm) KP1507 - 3/64A KP656 - 3/64A
1/16” (1.6 mm) KP1507 - 1/16A KP656 - 1/16A
Aluminum Electrode
(For use with Binzel Guns Only)
0.040” (1.0 mm) --------------- KP647 - 040A
3/64” (1.2 mm) --------------- KP647 - 3/64A
1/16” (1.6 mm) --------------- KP647 - 1/16A
LN-10
C-2 ACCESSORIES C-2
INPUT CABLE ASSEMBLIES:

K683-3 DUAL PROCEDURE SWITCH
K1797-25 Kit includes gun switch, and mountings for Lincoln
Consists of a 14-conductor control cable extension 25ʼ Innershield and Magnum guns, with 15 ft. (4.5m) con-
in length. trol cable and 5-pin plug with two leads to connect to
gun trigger.
K1797-50
Consists of a 14-conductor control cable extension 50ʼ
SPINDLE ADAPTERS:
in length.
Note: Extensions can only be connected up to 100ʼ Maximum K162H (Not required for LN-10 Bench Models)
length. Spindle for boom mounting Readi-Reels and 2" (51
mm) I.D. spools with 60 lb. (27.2 kg) capacity. User
K1520-1 115V/42V TRANSFORMER KIT mounted to appropriately prepared boom framework.
Includes an easily adjustable friction brake for control
Required to use LN-10 with Lincoln Power Sources
of overrun.
without 42VAC auxiliary and a 14-pin connector recep-
tacle. These power sources include the DC-250, DC-
When a 2" (51 mm) spindle is used with Readi-Reels
600 (Below Code 10500), DC-1000 and Pulse Power
or coils not on 12" (305 mm) O.D. spools, an adapter
500. Also can be used with older DC-400 models.
is required:
K590-4 WATER CONNECTION KIT Coil Adapter:

Includes water cooled gun tube fittings and self-sealing
outlet and inlet quick-connectors for mounting into the K1504-1 Permits 50 lb to 60 lb (22.7-27.2 Kg.) Coils
DH wire drive connection box.
to be mounted on 2” (51 mm) O.D. spindles.
K659-1 GAS GUARD REGULATOR K435 Permits 14 lb. (6 kg) Innershield coils to be
Adjustable flow regulator with removable adjustor key mounted on 2" (51 mm) O.D. spindles.
for CO2 and Argon blend gases. Mounts onto wire drive
gas inlet, and reduces gas waste and arc start "blow" by K468 Permits 8" (203 mm) O.D. spools to be mount-
reducing surge caused by excess pressure in supply
ed on 2" (51 mm) O.D. spindles.
hose.
Readi-Reel Adapters:
K1449-1 DUAL PROCEDURE
REMOTE CONTROL K363P Adapts Lincoln Readi-Reel coils of electrode
Includes a remote control box with a 16 ft. (5 m) length 30 lb. (14 kg) and 22 lb. (10 kg) to a 2" (51 mm) spin-
control cable with 4-pin plug for the mating receptacle dle. Durable molded plastic one piece construction.
on the bottom of the LN-10 control box. The remote con- Designed for easy loading; adapter remains on spin-
trol box contains a procedure selector switch and 2 dle for quick changeover.
rotating knob encoders, one controls arc voltage and the
other controls wire feed speed, which function the same K438 Adapts Lincoln Readi-Reel coils of electrode
as comparable controls on the LN-10 front panel, when 50-60 lb. (22.7-27.2 kg) to a 2" (51 mm) spindle.
the remote is connected and selected by the LN-10
Procedure Key.
GUN ADAPTERS (FOR 10 SERIES
K1450-”L” - Extension cables are available in lengths
“L” of 12, 16 or 25 ft. (3.6, 4.9 or 7.6) to match the con- WIRE DRIVE)
trol to Feeder cable length used. The LN-10 wire feeder is equipped with a factory
installed K1500-2 gun connection kit. This kit is for
K683-1 DUAL PROCEDURE SWITCH guns having a Tweco #2-#4 type connector. The LN-
10 has been designed to make connecting a variety of
Requires K686-2 Adapter for LN-10. Kit includes gun
guns easy and inexpensive with the K1500 series of
gun connection kits. Gun trigger and dual procedure
Magnum guns, with 15 ft. (4.5 m) control cable and 3-
lead connections connect to the single 5 pin recepta-
pin plug. K686-2 Adapter permits 3-pin plug and 5-pin
cle on the front of the feed head box.
gun trigger plug to be connected to LN-10 5-pin
Trigger/Dual Procedure receptacle.
LN-10
C-3 ACCESSORIES C-3
Magnum 200/300/400 Guns GUN RECEIVER BUSHINGS AND GUN ADAPTERS

The easiest and least expensive way to use Magnum K489-7 (Dual Schedule Fast-Mate Adapter)
200/300/400 guns with the LN-10 wire feeder is to This adapter installs directly into the wire drive feed-
order them with the K466-2 connector kit, or to buy a plate, to provide for use of guns with Fast-Mate or
completely assembled Magnum gun having the K466- European style gun connections. This K489-7 will
2 connector (such as the K497-21,-22,-23 dedicated handle both standard Fast-Mate and Dual Schedule
Magnum 400 guns and the K497-20,-21 dedicated Fast-Mate guns.
Magnum 200 guns).
Magnum 550 Guns

The easiest and least expensive way to use the
Magnum 550 guns with LN-10 wire feeders is to order The following Lincoln gun and cable assemblies are
the gun with the K613-2 connector kit, and install a compatible with 10 Series Wire Feed heads with
K1500-3 gun connection kit to the wire feeder. appropriate K1500 Gun Adapter:
Lincoln Innershield and Sub Arc Guns K126 (Requires K1500-1) Innershield gun and cable
All of these guns can be connected to the LN-10 by assemblies are rated at 350 amps, 60% duty cycle.
using the K1500-1 Adapter Kit. (Consult sales specifications for appropriate models)
Lincoln Fume Extraction Guns K115 (Requires K1500-1) Innershield gun and cable
The K556 (250XA) and K566 (400XA) guns require assemblies are rated at 450 amps, 60% duty cycle.
that a K489-7 Fast-Mate adapter kit be installed. (Consult sales specifications for appropriate models)
The K206, K289, and K309 K470 (With K466-9 requires K1500-2) Magnum 300
require only the installation of a K1500-1 connector in
GMAW gun and cable assemblies are rated 300
the LN-10 wire feeder.
amps, 60% duty cycle. (Consult sales specifications
for appropriate models)
Non-Lincoln Guns
Most competitive guns can be connected to the LN-10
by using one of the K1500 series adapter kits. K471 (With K466-9 requires K1500-2) Magnum 400
K1500-1 (Lincoln Innershield gun standard connection) amps, 60% duty cycle. (Consult sales specifications
for appropriate models)
Use this kit to connect the following guns: Guns having a
Lincoln standard innershield gun connector, Magnum
200/300/400 with K466-1 connector kit, and Magnum 550 K497 (With K466-9 requires K1500-2) Magnum 200
guns with the K613-1 gun connection kit. GMAW gun and cable assemblies are rated 200
amps, 60% duty cycle. (Consult sales specifications
K1500-2 (Tweco #2-#4 type connection) for appropriate models)
The K1500-2 gun adapter comes factory installed on the
LN-10 wire feeder. Use this adapter for guns that have a K541 (With K466-9 requires K1500-2) Magnum 400
Tweco #2-#4 connector. Such guns include Magnum Short Neck GMAW gun and cable assemblies are
200/300/400 guns with K466-2 connector kit, and complete- rated 400 amps, 60% duty cycle. (Consult sales
ly factory assembled Magnum guns that are factory specifications for appropriate models)
equipped with the K466-2 connector (such as the K471-21, -
22, and -23 dedicated Magnum 400 guns and the K497-20 K598 (With K613-7 requires K1500-3) Magnum 550
and -21 Magnum 200 guns). GMAW gun and cable assemblies are rated 550
K1500-3 (Tweco #5 connection) amps, 60% duty cycle. (Consult sales specifications
For Magnum 550 gun with K613-2 Connection Kit, for appropriate models) The following Lincoln gun and
and any other gun having a Tweco #5 connector . cable assemblies are equipped with a Fast-Mate™
connector. They can be used with 10 Series wire feed
K1500-4 (Miller connection) models by installing a K489-2 Fast-Mate™ adapter kit
and a K1500-1 Lincoln Gun adapter.
For any gun having a newer style Miller connector.
K684 Magnum "Super Cool" FM water cooled
amps, 100% duty cycle (CO2). (Consult sales specifi-
cations for appropriate models)
LN-10
C-4 ACCESSORIES C-4
K498 Magnum 200 FM GMAW gun and cable K1561-1 ROBOTICS INTERFACE
assemblies are rated for 200 amps 60% duty cycle. MODULE
(Consult sales specifications for appropriate models)
The module plugs directly into the LN-10 control board
and provides an interface to a properly equipped
K534 Magnum 250L FM GMAW gun and cable Fanuc robot. When installed and properly configured,
assemblies are rated for 250 amps, 30% duty cycle. the K1561-1 Robotics Interface Module allows com-
(Consult sales specifications for appropriate models) plete control of the welding process from the robot
controller.
K478 Magnum 300 FM GMAW gun and cable The Lincoln Electric Companyʼs Automation Center
assemblies are rated for 300 amps, 60% duty cycle. should be contacted for questions regarding installa-
(Consult sales specifications for appropriate models) tion or operation of the Robotics Interface Module.
K479 Magnum 400 FM GMAW gun and cable K1557-1 SWIVEL MOUNT
assemblies are rated for 400 amps, 60% duty cycle.
(Consult sales specifications for appropriate models) The K1557-1 Swivel mount attaches to the power
source. This kit includes a feeder adapter plate that
USING DUAL PROCEDURE WITH FAST-MATE allows the feeder to rotate on top of the power source.
GUNS The feeder can be easily separated from the swivel
There are a number of different options available for mount at any time. This option is compatible with the
using dual procedure with Fast-Mate guns. These K1556-1 Light Duty Caster Kit.
configurations are outlined below along with any addi-
tional required equipment.
K1556-1 LIGHT DUTY CASTER KIT
Using Dual Schedule with Fast-Mate Guns
This option provides 4 casters and all required hard-
on -10 Series Feeders ware to mount it to the Power Feed 10. This option is
compatible with the K1557-1 Swivel Mount.
Configuration 1
K489-7 Dual Schedule Fast-Mate adapter K1555-1 INSULATED LIFT HOOK
K575-Magnum 400 DS/FM gun (or competitive
DS/FM gun) For applications where an insulated lift hook is
required. This kit provides an easily installed, heavy
Configuration 2 duty insulated lift eye that mounts to the wire reel
K489-7-Dual Schedule Fast-Mate adapter stand mast. See the instructions provided with the kit
K683-1-Dual Procedure Switch (3 pin) for installation.
K686-2-"Y" adapter (3pin + 5 pin to 5 pin)
K*-Non-DS Fast-Mate gun (Magnum 450WC, K1634-1 WIRE REEL ENCLOSURE KIT
Magnum 200, Magnum 300, Magnum 400, and
others) The K1634-1 Wire Reel Enclosure Kit provides the
necessary parts to cover the wire and protect it from
excessive dirt and contamination. The kit is not for use
K1558-1 REMOTE SWITCH INTERFACE with 60lb coils (most 30 lb, 15kg, 44 lb fiber spools,
MODULE
and smaller coils will work). The kit includes a 2 part
plastic reel cover, a Magnum conduit adapter for the
The Module provides for user interface connection of incoming end of the wire feeder feed plate, and a
an external switch (flow switch, etc.) which must be short length of Magnum conduit to go between the
closed to enable the feeder welding operation. Also, reel cover and the feedplate.
the Module provides for interface connection of exter-
nal equipment (fume extractor, etc.) to the Moduleʼs
isolated relay contacts which actuate when the feeder
welding gas solenoid is activated (representing weld-
ing operation in process).
LN-10
D-1 MAINTENANCE D-1
MAINTENANCE Avoiding Wire Feeding Problems
Safety Precautions Wire feeding problems can be avoided by observing

the following gun handling and feeder set up proce-
WARNING dures:
• Do not kink or pull cable around sharp corners.
• Do not touch electrically live parts such • Keep the electrode cable as straight as possible
as output terminals or internal wiring. when welding or loading electrode through cable.
drive mechanism are “hot” to work and
ground and could remain energized several
• Do not allow dolly wheels or trucks to run over
seconds after the gun trigger is released. cables.
• Turn OFF input power at welding power
source before installation or changing • Keep cable clean by following maintenance
drive roll and/or guide tubes. instructions.
to system ground per the National
• Use only clean, rust-free electrode. The Lincoln
codes. electrodes have proper surface lubrication.
perform this installation. • Replace contact tip when the arc starts to become
unstable or the contact tip end is fused or
deformed.
throughout this manual. • Do not use excessive wire spindle brake settings.
Routine Maintenance • Use proper drive rolls, guide tubes and drive roll
pressure settings.
Drive Rolls and Guide Tubes
Periodic Maintenance
After feeding every coil of wire, inspect the drive roll
section. Clean it as necessary. Do not use a solvent Wire Drive Motor and Gearbox
for cleaning the idle roll because it may wash the
lubricant out of the bearing. The driver roll and guide Every year inspect the gearbox and coat the gear
tubes are stamped with the wire sizes they will feed. teeth with a moly-disulfide filled grease. Do not use
If a wire size other than that stamped on the roll(s) is graphite grease.
to be used, the roll(s) and guide tubes must be
changed. Every six months check the motor brushes. Replace
them if they are less than 1/4” long.
The drive rolls for .035” (0.9mm) through .052”
(1.3mm) cored electrode and 1/16” (1.6mm) through Gun and Cable Maintenance
3/32” (2.4mm) electrode have a double set of teeth so
they can be reversed for additional life. Drive rolls for See appropriate Operatorʼs Manual.
.023" (0.6 mm) through .052" (1.3 mm) solid elec-
trodes and aluminum sizes have no teeth, but use two Procedure for Removing Feedplate from
grooves so they also can be reversed for additional Wire Feeder
life.
1) Loosen the clamping collar screw using a 3/16"
See “Procedure to Install Drive Roll and Guide Tubes” Allen wrench. The clamping collar screw is
in the INSTALLATION section for roll changing accessed from the bottom of the feedplate. It is
instructions. the screw which is perpendicular to the feeding
direction.
Wire Reel Mounting - Readi-Reels and 2) Loosen the retaining screw, which is also
10lb through 30lb (4.5-14kg) Spools accessed from bottom of feeder, using a 3/16"
Allen wrench. Continue to loosen the screw until
the feedplate can be easily pulled off of the wire
No routine maintenance required. Do not lubricate 2”
feeder.
(51mm) spindle.
LN-10
E-1 TROUBLESHOOTING E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
LN-10
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Rough wire feeding or wire not feed- 1. Gun cable kinked and/or twisted.
ing, but drive rolls are turning.
2. Wire jammed in gun and cable.
3. Check for current position of

drive rolls relative to split wire
guide groove.
4. Drive rolls may not be seated

properly.
5. Gun cable dirty.
6. Worn drive roll.
7. Worn nozzle or cable liner.

9. Partially flashed or melted contact
tip
10. Incorrect drive roll pressure.
11. Improper liner, contact tip, or If all recommended possible areas

inner/outer wire guides. of misadjustment have been
checked and the problem persists,
12. Incorrect wire drive or gear ratio Contact your local Lincoln
selection on the control p.c. Authorized Field Service Facility.
board.
Variable or “hunting” arc. 1. Wrong size, worn and/or melted

contact tip.
2. Worn work cable or poor work

connection.
3. Loose electrode or work cable

connections.
4. Wrong polarity.
5. Gas nozzle extended beyond gun

tip or wire stickout too long while
welding.
6. Poor gas shielding on processes

requiring gas.
7. Improper power source selection

on the control p.c. board.
CAUTION
LN-10
Poor arc striking with sticking or 1. Improper procedures or techniques.
“blast-offs”, weld porosity, narrow
and ropy looking bead, or electrode 2. Improper gas shielding.
stubbing into the plate while weld-
ing.
Tip seizes in the diffuser. 1. Tip overheating because of prolonged

or excessive high current and/or duty
cycle welding.
Motor does not turn when trigger is 1. The wire drive motor may be over-
pulled. loaded. “Hxx” will be displayed on the
WFS display, where “xx” is the num-
ber of seconds until the wire drive
attempts to run again.
2. A jumper plug or K1558-1 Remote

Switch Interface Module must be
properly installed into connector J5.
3. Damaged wiring in the trigger circuit. If all recommended possible areas

of misadjustment have been
4. Control p.c. board failure. checked and the problem persists,
Contact your local Lincoln
The drive motor does not turn 1. Damaged leads to the drive motor. Authorized Field Service Facility.
although arc voltage is present
and the gas solenoid is on. 2. Damaged wire drive motor.
3. Damaged control p.c. board.
No control of wire feed speed. 1. Damaged leads to the motor

Motor turns. Gas solenoid operates tachometer.
properly and arc voltage is present.
Wire feed speed can be set on the
display, but has no control of the 2. Damaged tachometer.
wire feed speed.
3. Damaged control p.c. board
Wire feed motor turns and gas sole- 1. Power source is unable to provide arc
noid operates, but no arc voltage is voltage because of thermal shutdown
present. or other failure.
CAUTION
LN-10
Speed does not change when weld 1. Run-in and weld speeds are set
current flows. to the same value.
2. Current sensing reed switch is not

operating properly.
3. The wiring from the control p.c.

board to the weld current sensing
reed switch is damaged.
Voltmeter does not function proper- 1. The work sense lead (#21) or the
ly. Welding may or may not vary electrode sense lead (#67) may
from normal procedure. Wire feeds have intermittent or poor connec-
properly. tions.

3. Control p.c. board failure.

If all recommended possible areas
Cold feed forward or cold feed 1. The connector from the control checked and the problem persists,
reverse buttons on keypad do not p.c. board to the display p.c. Contact your local Lincoln
work, but motor control otherwise board or the connector from the Authorized Field Service Facility.
functions properly. display p.c. board to the keypad
are loose or improperly inserted.
2. Damaged keypad
3. Damaged display p.c. board.
Gas purge key does not operate 1. The connector from the control
the gas solenoid, but gas flow does p.c. board to the display p.c.
occur while welding. board or the connector from the
display p.c. board to the keypad
2. Damaged keypad
CAUTION
LN-10
Pressing the procedure key does 1. The connector from the control
not select between A - Remote - B. p.c. board to the display p.c.
board or the connector from the
2. Damaged keypad
Pressing the timer or control key has 1. Make sure that the DIP switches
no effect while not welding. on the control p.c. board are not
set for security mode.
2. The connector from the control

p.c. board to the display p.c.
3. Damaged keypad If all recommended possible areas

4. Damaged display p.c. board. checked and the problem persists,
5. Damaged control p.c. board. Authorized Field Service Facility.
Pressing the trigger key has no 1. The connector from the control
effect while not welding. p.c. board to the display p.c.
2. Damaged keypad
CAUTION
LN-10
One of the knobs changes the dis- 1. The display is in a mode that can
play, but the other doesnʼt. only use one encoder.
2. The connector from the control

p.c. board to the encoder p.c.
boards may be loose or improper-
ly inserted.
3. Damaged encoder p.c. board.
Neither knob changes the display. 1. The connector from the control
p.c. board to the encoder p.c.
boards may be loose or improper-
ly inserted.
3. Damaged encoder p.c. boards.

Displays & LEDʼs on keypad are off. 1. Power source is off. of misadjustment have been
The green and red LEDʼs on the checked and the problem persists,
control p.c. board are off. 2. Power source supply is not sup- Contact your local Lincoln
plying 42 VAC to the wire feeder Authorized Field Service Facility.
control box.
3. Damaged input power wiring in

the LN-10 control box.
Displays & LEDʼs on keypad are off. 1. The connectors from the control
The green and red LEDʼs on the con- p.c. board to the display p.c.
trol p.c. board are both blinking at board are loose or improperly
about one second intervals. inserted.
Displays & LEDʼs on keypad are off. 1. Damaged control p.c. board.
The green or red LED on the control
p.c. board is blinking at a very fast
or erratic rate.
CAUTION
LN-10
The K1449-1 remote control is not 1. The remote control Amphenol
functioning when the Procedure connection is not securely
LED is in the REMOTE position. attached.
2. Faulty wiring from the Amphenol

connector to the control p.c.
board.
3. Damaged remote control.
Dual procedure switch is not func- 1. Machine and remote control not
tioning at the gun. properly set for using a dual pro-
cedure switch at the gun
2. Disconnected or damaged wiring

between the wire drive and con-
trol box.
3. Damaged wiring in the LN-10 wire

drive.
4. Damaged wiring in the LN-10 con- of misadjustment have been
trol box. checked and the problem persists,
5. Damaged control p.c. board. Authorized Field Service Facility.
Wire feed speed is consistent and 1. DIP switch S1 is incorrectly set for
adjustable, but operates at the the wrong wire drive or gear ratio.
wrong speed.
CAUTION
LN-10
ʻErʼ is displayed on power up. 1. EEPROM error detected.
ʻGLPʼ is displayed. 1. Ground Loop Protection fault

occurred
2. GLP reed switch failure.
After pressing the trigger, wire 1. Power source work & electrode
feeds for a couple seconds, but sense lead polarity switch or
stops. The voltage display reads jumper is not correctly set.
less than 8.0 volts while the wire is
feeding. 2. Damaged wiring between the con-
trol p.c. board and the work and
electrode connections.
3. Damaged control p.c. board

The knobs do not control the com- 1. Limits are set for wire feed speed checked and the problem persists,
plete range of wire feed speed or or voltage. Contact your local Lincoln
voltage. Authorized Field Service Facility.
2. DIP switch S1 is incorrectly set for
the wrong wire drive or gear ratio.

Gas solenoid not operating properly 1. Inlet gas pressure exceeding 80

or intermittent. psi(5.5 bar). Verify that gas pres-
sure regulator is operating proper-
ly.
CAUTION
LN-10
E-9
TROUBLESHOOTING E-9
PC BOARD TROUBLESHOOTING c. If PC board is visibly damaged mechanically,

GUIDE - CONTROL P.C. BOARD inspect for cause, then remedy before installing a
replacement PC board.
WARNING If there is damage to the PC board or if replacing

ELECTRIC SHOCK can kill. PC board corrects problem, return it to the local
• Have a qualified individual install and Lincoln Electric Field Service Shop.
service this equipment.
• Turn the power source input power off
at the disconnect switch before work-
ing on this equipment.
• Do not touch electrically hot parts.
---------------------------------------------------------------------
Procedure for Replacing PC Boards
Before replacing a PC board which is suspected of

being defective, visually inspect the PC board in ques-
tion for any electrical or mechanical damage to any of
its components and conductors on the back of the
board.
a. If there is no visible damage to the PC board, install

a new one and see if this remedies the problem. If
the problem is remedied, reinstall the old PC board
to see if the problem still exists. If it does no longer
exist with old PC board:
1. Check the PC board harness connector pins for

corrosion, contamination, or looseness.
2. Check leads in the plug harness for loose or

intermittent connection.
b. If PC board is visibly damaged electrically, before

possibly subjecting the new PC board to the same
cause of failure, check for possible shorts, opens, or
grounds caused by:
1. Frayed or pinched lead insulation.
2. Poor lead termination, such as a poor contact or

a short to adjacent connection or surface.
3. Shorted or open motor leads, or other external

leads.
4. Foreign matter or interference behind the PC

boards.
CAUTION
F-1
LN-10
DIAGRAMS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
F-2
LN-10
DIAGRAMS
F-2
F-3
W IR IN G DIAGRAM (
LN -10 /STT-10 WIR E DR IVE)
CON NEC TOR CA VITY NUMBER ING SEQUENCE ELECT RICAL SYM BOL S PER E1537.
(NON LEAD SIDE OF CONNEC TOR )
ELEC TRO D E
CA BLE
J1 2 1 522 FR OM
J2 CURR EN T
J3 4 3 SENSOR
GA S
7 A 1
512
J4
14 A 8
P.M.
P1 1 2
TAC H .
P2
P3 3 4
J3 U R B
A
B W 2 1 3 4
1 7
P4 CHO KE PCB
LN-10
A
8 A 14 GE AR BO X
2 J1 1 3 4
539 2 1 3
ASSEM BLY
DIAGRAMS
H EAD
541 N.A.
2 1 3
P3 2 1 3
GU N
TRIGG ER AN D
67
560
520
522
541
539
512
519
R
B
561
P4 D U AL PROCE DURE N .A. HCOK E PC B ASSEM BLY N O T
SWI TCH INCLU D ED ON EARLIER WIRE
14 7 9 8 10 11 13 5 1 4 12 2 3 6 RE CEP TAC LE D R IVES.
J4
67
560
520
522
541
539
U
512
519
561
R
B
520
560
561
519
J5
C D B A K L F G H N I J E M J6
A B C D E
WIR E DR IVE R EC EPTACL E
3-9-2001E
M19828
F-3
F-4
BENCH MODEL DIMENSION PRINT
(20.46)
LN-10
(15.30)
(10.66)
DIAGRAMS
DIMENSION PRINT
(30.35) (14.43) (5.25)
7-2000
M 18903
F-4
F-5
14.71 5.25
7.81
6.55
4.44
2.42
12.74
10.40
2.25 4.08
LN-10
WIRE DRIVE
DIAGRAMS
3.00 DIMENSION PRINT

DIMENSION PRINT
7-2000
M18904
11.00
6.00
5/16-18UNC-2B
(4 PLACES)
F-5
F-6
10.92 Boom Model Control Box

Dimension Print
R .141
(3 SLOTS) 5.25 2.80
4.27
WARNING
2.63
14.65 13.75
12.75
LN-10
3
YEAR
WARRANTY
10.10
DIAGRAMS
DIMENSION PRINT
4.58
5-2-97
14.67 M18299
GRAPHICS SHOWN REPRESENT M17869-1.
F-6
WARNING
● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.
electrode with skin or wet clothing.
AVISO DE
● Insulate yourself from work and
ground.
Spanish
PRECAUCION
● No toque las partes o los electrodos ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
● Aislese del trabajo y de la tierra.
ATTENTION
French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
WARNUNG
German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
ATENÇÃO
Portuguese
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
WARNING
● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to guards off.
AVISO DE
remove fumes from breathing zone.
Spanish
PRECAUCION
● Los humos fuera de la zona de res- ● Desconectar el cable de ali- ● No operar con panel abierto o
piración. mentación de poder de la máquina guardas quitadas.
● Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilación o
ATTENTION
aspiración para gases.
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones protection enlevés.
WARNUNG
de travail.
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
ATENÇÃO
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos
● Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
Introduction
Your Veeder-Root brand C628 Rate Meter is one model in a family of 1/8 DIN units which
offers breakthrough display technology as well as easy-to-program single-line
parameters. Designed to provide instant visual feedback regarding an application’s key
input value, the C628 not only has a 0.71” high LED display (27% larger than other 1/8
DIN units), but also the ability to change display color based on process status
(programmable parameter in Operation Mode). Easy programming is made possible via a
help function and a secondary legend display.
This manual will guide you through the installation and wiring of your C628 unit with
information on proper panel mounting and rear terminal layout and wiring instructions.
In addition, the instrument’s operation and programming modes are thoroughly
explained. The Operation Mode provides day to day operation and allows editing of
preset values. The Program Mode enables the configuration of various parameters prior
to initial operation. These parameters include those for basic configuration as well as
other settable features which will enhance the functionality and usability of the device.
This manual also provides
information on the C628 Rate
Meter’s alarms; transistor,
relay and linear outputs;
product specifications; and
ordering and warranty Technical Manual
procedures. 702138-0003
Veeder-Root brand
Series C628
Features
• AWESOME 0.71” high digit LED display
Index
Installation
Rate Meter
• Programmable color change display based on Panel Mounting page 2 (C628-4XXX)
an event Wiring page 3
Operation
• Programmable help function and secondary Front Panel page 4
legend display Operation Mode page 5
• Display configurable for update time, min. Programming
number of pulses, and forced zero time Program Mode page 6-10
Appendix A
• Optional linear output relative to rate
Specifications page 11
• Choice of NPN, PNP, or magnetic primary General
input Ordering Information page 12
• Filter speed settable for 20, 200, or 10,000 Hz Warranty page 12
• Standard outputs: two NPN transistors & one
relay (optional 2nd relay)
• Front panel reset enable and alarm lockout
• Optional RS-485 plug in card
• CE approved
I N S T A L L A T I O N
PANEL MOUNTING
100mm
VEEDER-ROOT
OP1
82344
OP2
48mm
PGM RST
96mm 10mm
92mm +0.5 -0.0
PANEL 45mm
CUTOUT +0.5 -0.0
SIZE
The instrument can be mounted in a panel with a thickness of up to 6mm. The

cutout(s) should be made based on the recommended panel opening illustrated in the
Mounting Grooves drawing above.
Insert the unit in the panel through the cutout. Ensure that the
panel gasket is not distorted and the instrument is positioned
squarely against the panel. Slide the mounting clamp into place
on the instrument, as shown to the left, and push it forward until
it is firmly in contact with the rear face of the mounting panel and
the tabs on the bracket arm are seated in the mounting grooves
20
on the side of the unit.
17 18 19
24 23 22
14 15 16
The electronic components of the instrument can be removed from
10 11 12
6 5 4 3 2 the housing after installation without disconnecting the wiring.

To remove the components, grip the side edges of the panel and
8 7
pull the instrument forward. Take note of orientation of the unit

for subsequent replacement in the housing.
Bracket Arm
2
I N S T A L L A T I O N
WIRING
REAR TERMINAL CONNECTIONS
Power Supply RS-485 Comm.

+ VDC - (opt.) Relay 1
B A COM
14 15 16 17 18 19 20
+ 24 23 22
10 11 12
Linear
Output Relay 2
(opt.) (opt.)
- 8 7 6 5 4 3 2
Input Power
For an AC powered unit, Terminal #13 serves as the line
or Hot side connection for AC powered units and as the
Input Common
NPN Out 1
Input B
(sec. lockout)
(display hold)
Aux. Power
NPN Out 2
Input A
Common
Digital In 2
Digital In 1
positive side for DC powered units. The neutral side for

(opt.)
(LO)
(HI)
AC powered units and the negative side for DC powered

units are connected to Terminal #14.
Count Inputs
Transistor Outputs
Terminal #2 is the connection for Input A, which is programmable to be
Your unit comes standard with 2 NPN outputs which are activated by
the primary rate channel. Terminal #1 is the secondary input to get the
each of the alarms. Transistor Output 1, which is tied to the High Alarm
ratio of A/B. The common connection for both inputs is Terminal #3.
Value, is on Terminal #7. Transistor Output 2, which is tied to the Low
Alarm Value, is on Terminal #9. Terminal #8 serves as the common
Control/Digital Inputs connection for both transistor outputs.
A contact closure or NPN signal can be used to activate preconfigured
functionality. Terminal # 5 is used for a display hold function, while Relay Outputs
Terminal #6 is a security function, that when active, will prohibit entry
Your unit comes standard with a relay output which is tied to the High
into Program Mode. Terminal #8 serves as the common for both of these
Alarm Value. Terminal #19 is NC, Terminal #20 is common, and
inputs.
Terminal #21 is NO. A second relay output tied to the Low Alarm Value
can be added as an option at the time of order or later installed in the
Auxiliary Power Output field. Terminal #22 is NC, Terminal #23 is common, and Terminal #24 is
A 9 - 15 VDC for powering external sensors and encoders up to 125 mA NO.
can be accessed by connecting the positive supply side of the sensor to
Terminal #4 and the negative side to Terminal #8. Serial Communication
An RS-485 communication board, utilizing ASCII protocol, can be
Linear Output installed as an option. Terminals #16 & #17 serve as the B and A
An option board may be installed that provides a 10 bit linear output connections respectively, while Terminal #18 is connected as the
signal relative to the Rate Value. Terminal #12 is the positive side of the common.
connection, and Terminal #10 is the negative side. The default range of
the output is 4-20 mA, but can be changed via the front panel to 0-20
mA, 0-10 VDC, 2-10 VDC, 0-5 VDC, or 1-5 VDC. Terminals 11 & 15 are not used.
3
O P E R A T I O N
FRONT PANEL
Primary Display
VEEDER-ROOT
OP1
Output Indicators
82345 H
OP2
Secondary Display
PGM RST
Down Key Scroll Key Program Key Reset Key
Key Functions Display Functions

Key Function Display Function
Down In Operation Mode: Used in edit operation to decrement Primary In Operation Mode: Default display is the rate value.
the digit highlighted by the Scroll key. Can be scrolled using the program key to display the
In Program Mode: Used in Edit Operation to decrement process time and alarm values. If the "Help" function
the digit highlighted by the Scroll key, if the setting is is enabled, this display will first show the parameter
a numerical value, or present the next in the series of description for 3 seconds (see page 5 for example).
choices for that parameter. In Program Mode: Displays the value or selection for
the current parameter. If the "Help" function is
Scroll In All modes: Moves the unit into Edit Operation,
enabled, this display will first show the parameter
which is indicated by the left most digit flashing.
description for 3 seconds (see page 6 for example).
Successive presses of the key are used to move to the
digit to be edited. Wrap around will occur from least Secondary In Operation Mode: Indicates alphabetically which
significant digit to most significant digit. parameter is being viewed on the primary display.
Program In Operation Mode: Used to move between the rate In Program Mode: Provides a 1 digit alpha or numeric
value display, process time display, & the alarms and to character to indicate which parameter value is being
enter an edited alarm value. Holding the key down shown on the primary display.
for 3 seconds will cause the unit to enter Program
Output In Operation Mode: OP1 illuminates when Output 1 is
Mode.
Indicators active. OP2 illuminates when Output 2 is active.
In Program Mode: Used to move from one parameter to
In Program Mode: No function.
the next and enter the edited parameter values.
Holding the key down for 3 seconds will cause the
unit to return to Operation Mode.
Reset In All modes: No function.
Down & In All modes: Will abort an Edit Operation and return
Scroll the alarm/parameter to its previous value.
together
4
O P E R A T I O N
OPERATION MODE
CHANGING A PARAMETER VALUE

VEEDER-ROOT Default display is the rate value. VEEDER-ROOT
OP1
Use the Scroll Key to move from left to
34567
OP1
23456 right and highlight the digit that needs

OP2 OP2
H to be changed. Wrap around will occur

PGM RST
from the least significant to the most
PGM RST
significant digit.
PGM
VEEDER-ROOT
OP1
Pressing the Program Key will cause the VEEDER-ROOT Use the Down Key to decrement the
rAtE display description to appear on the
OP2 OP1
33567 digit until the desired value appears.

OP2
main display.* If there is no key activity H The display will wrap around from 0 to
PGM RST
for 3 seconds, the primary display will 9.
switch back to the rate value. PGM RST
PGM
PGM PGM
VEEDER-ROOT
OP1
Continued pressing of the Program Key VEEDER-ROOT After the desired digits have been
Hi AL will scroll through the Parameters. (See
OP2 OP1
Hi AL changed, press the Program Key to enter

OP2
Parameter Sequence below.) The full the new value. The new value will
PGM RST
parameter description will appear on the appear on the main display without any
main display.* PGM RST
flashing digits. Press the Progam Key
again and the parameter description will
appear on the main display.
VEEDER-ROOT
OP1
To change a Parameter value, press the
34567 Scroll Key. If there was no key activity

OP2
H for 3 seconds, the Preset value will

PGM RST
appear (one digit description shown on
secondary display); however, press the
Scroll Key in order to edit. The unit will * Parameter descriptions will not ** Edit Operation cannot be
now be in Edit Operation as signified by appear on the primary display if the accessed if the Preset Lock has
the most significant digit flashing.** "Help" function has been disabled. been enabled in Program Mode.
PARAMETER SEQUENCE
Rate Value High Alarm Value
rAtE r Function: Displays present rate value Hi AL H Function: Defines the rate value at or
Range: 0 to 99999 above which Alarm 1 will activate
PGM Adjustment Range: 0 to 99999
Process Time Default Value: 1000

Pr ti P Function: Displays present process time
PGM
(an inverse speed calculation) Low Alarm Value

PGM Range: 0 to 99999
Lo AL L Function: Defines the rate value at or
below which Alarm 2 will activate
[can indicate travel time through a
conveyorized oven] Adjustment Range: 0 to 99999
Default Value: 10
5
P R O G R A M M I N G
PROGRAM MODE
ENTERING PROGRAM MODE AND BASIC OPERATION

The Program Mode can be accessed from the VEEDER-ROOT
OP1
Operation Mode by holding the Program Key

23456
OP2
for 3 seconds.
PGM RST
for 3 seconds
PGM
no key activity Edit Operation
The name of the first parameter will appear VEEDER-ROOT for 3 secs. or VEEDER-ROOT
OP1 OP1
on the primary display.*

CALdP 0.0000
OP2 OP2
.C
PGM RST PGM RST
PGM
Pressing the Scroll Key or no key activity for

PGM 3 seconds will display the value for that
parameter. The secondary display will
Successive presses of the Program Key will VEEDER-ROOT
OP1
indicate the one digit identifier for the
scroll the display through the remaining
CAL
OP2
parameter. The digit in the secondary

parameters in the Program Mode. To exit
display will flash to indicate the unit is in
Program Mode, hold the Program Key for 3 PGM RST Program Mode. If the Scroll Key was
seconds.
pressed (instead of waiting 3 seconds), the
unit is in Edit Operation, as indicated by the
MSD flashing. If there had been no key
activity for 3 seconds, press the scroll key to
* Parameter names will not appear on the enter Edit Operation (MSD flashing). Use
main display if the "Help" function has been the scroll and edit buttons to change the
disabled in Program Mode. value as in Operation Mode, described on
page 5. Press the Program Key to enter any
changes.
PARAMETER SEQUENCE
Calibration Factor Decimal Point
CALdP .C Function: Sets the decimal point position for the calibration factor display
Adjustment Range: 0 to 0.0000
Default Value: 0.0
PGM
Calibration Factor
CAL C Function: Used to scale the input into engineering units by multiplying this value by the input frequency
Adjustment Range: 0.0001 to 9.9999
Default Value: 1.0000
PGM
6
PROGRAM MODE Continued
Decimal Position
d E c Pd Function: Set the decimal point position for the rate and preset displays
Adjustment Range: 0 to 0.0000
Default Value: 0
PGM
Rate Mode
r A t <> r Function: Defines how the input pulses will be applied to the rate value
Adjustment Range:
A A_b Ati<>
A: Inputs on the A A/B: Divides the rate of A Time: Displays the
channel increment the the A channel by the rate frequency of Input A as an
total of the B channel to inverse speed which, for
display a ratio between example, can indicate
the inputs travel time through a
conveyorized oven
Default Value: A
PGM
Input Type
1 n P u ti Function: Programs the unit to match the electrical characteristics of the input signal
Adjustment Range:
Sin Src <>AG
Sinking: The unit will Source: The unit will Magnetic: The unit will
accept a NPN or dry accept an PNP input accept a magnetic input
contact input which sinks which sources voltage from 0.5 to 30V peak
voltage to common
Default Value: Sinking
PGM
Filter Speed
SPEEd F Function: Enables the debounce filter of the meter to properly match the application
Adjustment Range:
20 200 10000
20: The unit will accept 200: The unit will accept 10,000: The unit will
up to 20 pulses per up to 200 pulses per accept up to 10,000
second. Generally used second. Generally used pulses per second.
with contact inputs to for higher speed contact Generally used with high
eliminate false counts inputs or to filter noise speed electronic inputs
caused by contact bounce on electronic signals in and encoders
low speed applications
Default Value: 10000
7
PGM
Display Update Time

uPdAt U Function: Sets the amount of time between display updates
Adjustment Range:
0.1 0.25 0.5 1 to 1 0
0.1 sec. 0.25 sec. 0.5 sec. 1 to 10 sec.
Default Value: 1
PGM
Display to Zero Time

0 ti 0 Function: Displays minimum input frequency by setting the amount of time after no pulses are received, when
the display will show zero
Adjustment Range:
0.1 0.25 0.5 1 to 1 0
0.1 sec. 0.25 sec. 0.5 sec. 1 to 10 sec.

(10 Hz.) (4 Hz.) (2 Hz.) (1 Hz to 0.1 Hz)
Default Value: 1
PGM
Minimum Pulses
PulS P Function: Sets the minimum number of pulses to be received before the display will update the rate value.
Note: Display Update Time and Minimum Pulses must be realized before the display will update
Adjustment Range: 1 to 99
Default Value: 10
PGM
Startup Suppression
Strt S Function: Determines the delay period that will occur after power-up before alarm operation is possible
Adjustment Range: 0 to 99 secs.
Default Value: 0
PGM
Retransmission Enable/Select
rt En t Function: Determines whether a voltage/current is an output, and if so, which range
Adjustment Range:
nonE 0-5u 0-10u 0-20A 4-20A
4-20 mA
None 0-5 Volts 0-10 Volts 0-20 mA
Default Value: None

PGM
8
Retransmission Scale Minimum (Appears only if a current/voltage is selected)

rt Lo L Function: Defines the lower end of the linear scale for the retransmission output by defining the value equated
to the minimum output signal - i.e. for a 4-20 mA output, this would be the value corresponding to 4 mA
Default Value: 0
PGM
Retransmission Scale Maximum (Appears only if a current/voltage is selected)

rt Hi H Function: Defines the upper end of the linear scale for the retransmission output by defining the value equated
to the maximum output signal - i.e. for a 4-20 mA output, this would be the value corresponding to 20 mA
Default Value: 100
PGM
Serial Communication Enabled

Co<>S c Function: Activates the RS-485 communication option board
Adjustment Range:
nonE Fit
None: No communication Fitted: A communication

board installed board is installed in the
unit
Default Value: If ordered from the factory with the RS-485 board, the default will be "fitted". If the board is
installed in the field, this parameter will need to be changed from its default of "none"
PGM
Communication Address (Appears only if communication board is installed and activated)

Addr A Function: Defines the unique communication address of the counter
Default Value: 1
PGM
Baud Rate (Appears only if communication board is installed and activated)

bAud b Function: Selects the serial communication speed
Adjustment Range:
1200 2400 4800 9600
1200 BPS 2400 BPS 4800 BPS 9600 BPS
Default Value: 4800

PGM
9
Display Color Change

Color o Function: Defines the color of the display for prior to and after the preset value is reached
Adjustment Range:
rEd GrEEn Gn_rd rd_Gn
Red: The display will Green: The display will Green to Red: The Red to Green: The
always be red always be green display will be green prior display will be red prior to
to the Alarm value being the Alarm value being
reached. It will turn red reached. It will turn green
after the Alarm has been after the Alarm has been
reached reached
Default Value: Green to Red
PGM
Preset Lock
Loc/ / Function: Determines whether the Preset Values can be changed via the front panel
Adjustment Range:
En diS
Enable: Preset values Disabled: Preset values
are read only can be viewed and
changed
Default Value: Disable
PGM
Help Prompt
HELP h Function: Determines whether the multi-character parameter name will appear on the main display for 3
seconds prior to the parameter value appearing
Adjustment Range:
HLP Y HLP N
Help - Yes: Multi-character parameter Help - No: Only the parameter values
descriptions will appear on the primary will appear on the primary display.
display. The value associated with that The parameter can be identified by a
parameter will appear by pressing the single digit in the secondary display
scroll key or waiting for 3 seconds
Default Value: Help - Yes
10
A P P E N D I X A
SPECIFICATIONS
Count Inputs Communication

Type: Sinking/Sourcing or Contact Closure Type: Serial asynchronous, UART to UART
Frequency: 10 kHz max. Data Format: Open ASCII: One start bit, even parity seven
Logic: Low < 2.0 VDC, High > 3.0, 30V max. data bits, one stop bit
Impedance: 10 KΩ to common - Sourcing Physical Layer: RS-485
4.7 KΩ to +Voltage - Sinking Maximum Zones: 99
Magnetic Input: 0.6 to 30V peak Baud Rate: Selectable from 9600, 4800, 2400, or 1200
Control Inputs Electrical

Type: Sinking, Edge Sensitive Supply Voltage: 90-264 VAC, 50/60 Hz, or 20-50 VAC/VDC
Logic: Low < 2.0 VDC, High > 3.0 Power Consumption: 4 Watts
Impedance: 4.7 KΩ to +Voltage Access. Power Supply:9-15 (unregulated VDC), 125 mA max.
Response Time: 25 ms
Function: Input 1: Display Hold
Input 2: Security Lockout Display
Type: Red/Green, 7 segment LED, 5 digits primary
display, single digit secondary display
Outputs Height: 0.71" (18mm) primary display,
Solid State: NPN open collector, 30 VDC max, 100 mA max. 0.3" (7mm) secondary display
Relay: SPDT, 5A resistive @ 110VAC Annunciators: Output 1 & 2 status
Latency: 75 µ seconds, plus 8 ms for relay pull-in
Physical
Linear Outputs Dimensions: 48mm x 96mm, 110mm deep
Ranges: 0-20mA, 4-20mA, 0-10V, 2-10V, 0-5V, 1-5V Mounting: Panel mount (mounting bracket supplied),
Accuracy: ±0.25% (mA at 250Ω, V at 2kΩ); 45mm x 92mm cutout
degrades linearly to ±0.5% Terminals: Screw type - combination head
Resolution: 8 bits in 250ms (10 bits in 1s typ.) Front Panel Rating: NEMA 4X/IEC IP65
Update: Approximately 4/s Case Material: GE Lexan 940
Load Impedence: mA Ranges: 500Ω max.; V Ranges: 500Ω min. Weight: 0.56 lbs.
Approvals Environmental
General: CE Operating Temp.: 0° to 55° Celsius, 32° to 131° Fahrenheit
EMC Susceptibility: Complies with EN50082-1: 1992, Storage Temp.: -20° to 80° Celsius, -4° to 176° Fahrenheit
EN50082-2: 1995 Relative Humidity: 20% to 95% non-condensing
EMC Emissions: Complies with EN50081-1: 1992,
EN50081-2: 1994
Safety: Complies with EN61010-1: 1993
11
G E N E R A L
ORDERING INFORMATION
C628 - 4
2nd Relay Option Power Supply

0 None 0 90-264 VAC
1 2nd Relay 2 20-50 VAC/VDC
Linear Output Serial Communication

Option Option
0 None 0 None
3 Linear Output 5 RS-485
Additional outputs and options can be
field installed through plug-in boards
which can be ordered separately.
Description Part #
Relay Board T50-001
DC Linear Board T50-003
RS-485 Comm. Board T50-005
WARRANTY
Standard products manufactured by the Company are warranted to be the Company consents to have returned shall be shipped F.O.B. the
free from defects in workmanship and material for a period of one year Company's factory. The Company cannot assume responsibility or
from the date of shipment, and products which are defective in accept invoices for unauthorized repairs to its components, even though
workmanship or material will be repaired or replaced, at the option of the defective. The life of the products of the Company depends, to a large
Company, at no charge to the Buyer. Final determination as to whether a extent, upon the type of usage thereof, and THE COMPANY MAKES NO
product is actually defective rests with the Company. The obligation of WARRANTY AS TO FITNESS OF ITS PRODUCTS FOR SPECIFIC
the Company hereunder shall be limited solely to repair and replacement APPLICATIONS BY THE BUYER NOR AS TO PERIOD OF SERVICE
of products that fall within the foregoing limitations, and shall be UNLESS THE COMPANY SPECIFICALLY AGREES OTHERWISE IN
conditioned upon receipt by the Company of written notice of any alleged WRITING AFTER THE PROPOSED USAGE HAS BEEN MADE KNOWN TO
defects or deficiency promptly after discovery within the warranty period, IT.
and in the case of components or units purchased by the Company, the THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL
obligation of the Company shall not exceed the settlement that the OTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDING, BUT NOT
Company is able to obtain from the supplier thereof. No products shall LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS
be returned to the Company without its prior consent. Products which FOR A PARTICULAR PURPOSE.
Danaher Controls
Printed in U.S.A. 1675 Delany Road
702138-0003 Gurnee, IL 60031–1282
March 1998 Phone: 847.662.2666
Revision none Fax: 847.662.6633
12
Active Design Assures Reliability
Cannot Jam in “Flow OK” Position
Models Span 0.08 to 60.0 GPM
Adjustable Trip Point
Information in this document was correct at the time of
printing; however, specifications are subject to alteration as
Proteus Industries’ continuous improvement processes
establish new capabilities.
© Proteus Industries Inc. May 2007

Document ID 100DS-003
Proteus Industries Inc.
100 Series
Flow Switches
Technical Reference Manual
Can we Improve? Tell our President!

Can we improve our product, our support or this manual?
We are committed to continuous improvement and welcome your help. Fax, mail or e-mail your ideas to
me, Jon Heiner.
If you include your phone number, I will give you a personal reply. Or if you prefer, call me on my direct
line.
Phone: (650) 943-4102 Fax: (650) 965-9355 E-mail: Jon@proteusind.com
Proteus 5-Year Warranty

A full statement of our Warranty is available at our website, www.Proteusind.com .
Page 1 of 15 Print/Review Date: 28 December 2004

Doc No: 100TRM-001 Review Date: 28 December 2004
Contents
Page
Section 1: Overview 3
Section 2: Flow Ranges and Pipe Connections 3
Section 3: How do they work? 5
Section 4: Physical Installation 5
Pipe or tubing mounting

Panel mounting
Plumbing Connections
Filtering
Fluid Temperature Range
Section 5: Electrical Connections 8
Relay output versions

Transistor output versions
Section 6: Setting the Trip Point 10
Relay output versions

Transistor output versions
Section 7: Maintenance 11
Section 8: General Trademarks 13
Section 9: Reference Documents 13
Circuit Diagrams
Current Data Sheet for 100 Series Flow Switch is available at

www.proteusind.com
Page 2 of 15 Review/Print Date:28 December 2004

Section 1: Overview
Metering flow switches such as the Proteus 500 and 800 Series with Hall Effect sensors may be
better suited for interfacing with current electronic control systems. Please contact us for
assistance in selecting a sensor best suited to your application!
Proteus 100 Series Fluid Flow Switches are designed to monitor the flow of fluid through a line. They are
frequently used to assure that water is flowing in a cooling circuit, however they may be used in a wide
variety of applications with many different fluids.
Section 2: Flow Ranges and Pipe Connections

Table 1 lists the model numbers and flow ranges. Model 100XXX versions can be configured in one of
three different ranges, depending on the placement of the supplied blanking plugs.
• To operate across the A to B flow path, blanking

plugs must be placed in ports C and D.
• To operate across the B to C flow path, blanking

plugs must be placed in ports A and D.
See Note below Table 1
• To operate across the D to C flow path, blanking

plugs must be placed in ports A and B.
Connection Flow Range

Model Size Inlet Outlet
Number
Port Port
XXX = 24 or 110 GPM LPM
100XXX 1/4" FNPT Selectable Various
101XXX 1/4" FNPT 0.1 – 1.0 0.4 – 4.0 A B
105XXX 1/4" FNPT 0.5 – 2.5 1.9 – 9.5 B C
103XXX 1/4" FNPT 0.8 – 6.0 3 – 27 D C
104XXX 1/4" FNPT 0.06 – 0.6 0.2 – 1.9 A B
150XXX 1/2" FNPT 1.5 – 12 6 – 45 D C
155XXX 1/2" FNPT 4 – 20 15 – 75 D C
160XXX 3/4" FNPT 6 – 30 22 – 110 D C
170XXX 1" FNPT 10 – 60 35 – 225 D C
Table 1: Flow Ranges and Pipe Connections

NOTE!
When the flow direction is from B to C or from C to D it is necessary to reverse the connections to
the induction coil for proper operation of the flow switch.
1. Remove the four screws securing the

electronics unit to the flow sensor body.
2. Gently remove the electronics unit from the

sensor body to locate the black and white
wires connected to the induction coil by
spade electrodes.
3. Disconnect the spade connectors from the

induction coil.
4. Reconnect the White wire to the spade

terminal B
5. Reconnect the Black wire to the spade

terminal W
6. Reposition the electronics unit to align with the

screw holes in the corner of the flow sensor
body.
.

Section 3: How do they work?
The rotor spins when liquid flows through the sensor body. Induction
coil
Magnets in the rotor create a voltage in an induction coil mounted
in the sensor body. The amplitude of the induced voltage is at
a maximum when the magnet is immediately adjacent to the coil. Rotor
The amplitude of the induced voltage is proportional to the
rotational velocity of the rotor and the linear velocity
of the liquid as it passes through the sensor body.
This amplitude of the induced voltage is measured by a simple electronic circuit that compares it to a user-
set trip point voltage.
Relay Interface: When the induced voltage is greater than the voltage achieved at a user-selelected trip
point flow rate, the relay is energized. If the induced voltage is less than the voltage achieved at the user-
selected trip point flow rate or if the fluid stops flowing, power to the relay is shut off, and the relay is de-
energized. The de-energized state is called the relay's normal position. The change of state of the relay is
interpreted by the user’s equipment to control other system functions.
Transitor Interface: When the induced voltage is greater than the voltage achieved at a user-selected trip
point flow rate a transistor is turned ON. If the induced voltage is less than the voltage achieved at the user-
selected trip point flow rate, of if the fluid stops flowing, a transistor will turn OFF. The change is state of the
transistor is interpreted by a user-supplied interface to control other system functions.
Section 4: Physical Installation
CAUTION!
It is generally undesirable to mount any plumbing connections directly over

electronic controls or instruments.
WARNING!
If the 100 Series 100 Series Flow Switch is mounted in a vertical pipeline, any leakage from the
topmost connection could enter the unit and cause permanent damage to the electronics..
Pipe or tubing mounting
If rigid piping or tubing is used, the flow switch may be supported by direct connection to the pipe or tubing.
Panel mounting
To mount the sensor behind a panel, two of the faceplate securing screws will need to be replaced with
longer screws to compensate for the thickness of the panel. Ensure that the screws are not so long that
they will touch the bottom of the tapped hole, or rip through the back of a plastic body if over-tightened.
Evenly space up to six holes for 8-32 screws on a 2.5” circle. Using the two holes on the horizontal plane is
usually sufficient to support smaller flow sensors and all plastic sensors. If you wish the rotor to be visible,
cut a 1¾” diameter hole with the same center.

Figure 1: Panel Mounting of 100 Series Flow Switch
1. Remove screws holding the faceplate to the sensor body.

2. Place the sensor behind the panel and insert the longer screws you have selected.
3. Secure the screws in the body with a torque of ~ 10 in-lb. (Finger tight with a flat-blade
screwdriver.).
Plumbing Connections
Note
Before connecting a flow switch into your fluid line, verify that the normal flow rates expected
in that line are within the operating range of the sensor as shown in Table 1
Extended use above the rated maximum flow rate of the sensor will reduce its useable life.
Note
It is recommended that connections to the stainless steel flow sensor be made with stainless steel
or materials of similar chemical inertness to minimize potential corrosion damage.
Note
The flow response of the sensor, and thus its output response may be dependent on the internal diameter
(ID) of an incoming pipe, or the ID of a tube connection.
If the ID of your pipe or tube fitting where it connects to the inlet port is LESS than the value shown in
Table 2, pre-calibrated trip points may be invalid.

Connection Minmum ID of pipe or connection

Model Pipe Inlet Outlet Celcon Polypropylene Brass or
Size Port Port Stainless Steel
104X ¼” NPT A B Not Sensitive
101X ¼” NPT A B 0.28” 0.28” 0.28
105C ¼” NPT B C 0.28”
105 B or SS ¼” NPT D C 0.35” 0.28
103X ¼” NPT D C 0.28” 0.35” 0.35
150X ½” NPT D C 0.54” 0.54” 0.60
155X ½” NPT D C 0.54” 0.54” 0.60
160X ¾” NPT D C Not Available 0.81
170X 1” NPT D C Not Available 0.81
Table 2: Minimum ID of pipe or connection
Note
The flow response of a 100 Series Flow Switch may be dependent on the form of a device attached to the
inlet connection and other closely located up-stream devices.
Elbows, T-pieces, valves and filters located immediately up-stream from the flow sensor can introduce
swirling motion to the liquid flow. The swirling motion reduces the linear velocity of the flow stream.
We recommend that a straight run of pipe of more than 10 x pipe ID be used between the flow switch and
any up-stream devices to minimize these effects.
Appropriate calibration procedures must be used to provide an accurate trip point settings in systems in
which elbows or T-pieces that must be attached directly to the inlet connection.
100 Series Flow Switch are typically unaffected by the form or proximity of devices on their downstream
side.
Sensor Orientation
For the best results, 100 Series Flow Switches should be mounted with the faceplate in the vertical plane.
Mounting the device with the flow connections uppermost can help eliminate entrained air from your system.
NPT pipe thread connections
Pipe threads seal by making metal-to-metal or plastic-to-plastic contact between male and female
components. Consequently they are particularly prone to the damaging effects of galling, which occurs
when two surfaces move against each other under pressure. When installing pipe threads it is essential to
use a high quality lubricating and sealing material.
WARNING
Do NOT use anaerobic pipe sealants such as LOCTITE or SWAK brand sealants with
these sensors. The aggressive chemical nature of these materials will cause
cracking of polysulfone faceplates.

• Use Teflon tape or a PTFE-based liquid sealant to provide lubrication for the junction and a leak-tight
connection at both input and output connections. Real-Tuff and Hercules are two of many suitable
brands of PTFE-based sealants.
• Do not over-tighten the connection. Refer to instructions for installation of the mating fittings for
information on torque requirements.
• Leak testing of all connections in your flow circuit is recommended. Pressurizing the system with air and
external testing with a dilute soap solution can help identify leaking connections.
Filtering
Your circulating fluid may contain particles. While not essential to the operation of the flow sensor, it is good
practice to filter your fluid. A 100-micron filter is often used to remove rust and other particles from the fluid.
This can increase the lifetime of pumps and other fluid system components as well as reducing wear in the
sensor.
Fluid Temperature Range
Flow sensors with plastic bodies should not be used above 75°C. Metal bodies with metal faceplates may be
used with liquids to higher temperatures. The induction coil should not be used for temperatures above
110°C.
For higher temperature situations, contact Technical Support at 650 964 4163 or Tech@proteusind.com
for assistance in selecting the flow sensor best suited to your application.
Section 5: Electrical Connections
Relay Output Versions
Note
Only personnel familiar with the electrical circuit and control functions of the system in which
the sensors are to be included should perform installation of this product.
24V-DC versions of the 100 Series Flow Switch are fitted with a five-core cable for connection to the user’s
control system. 110V~AC versions are fitted with a two core power cable and plug, and a three-core cable
for connection to the user’s control system. Color codes and wiring connections are shown in Tables 4 and
5.
24V-DC wiring
Color Function
Brown + 24 VDC
White Ground or - VDC
Red Normally Open NO contact
Green Normally Closed NC contact
Black Relay common contact
Table 4: Wiring Diagram for 24V-DC Flow Switch

110V~AC wiring
Color Function
Red Normally Open NO contact
Green Normally Closed NC contact
Black Relay common contact
Table 5: Wiring Diagram for 110V~AC Flow Switch
Transistor Output Versions
If the part number of your flow switch ends in N, for example 0150C24N, the unit does NOT have an output
relay. In these versions, the state of an output transistor is monitored by the user’s control system.
Units with a transistor output are shipped with a four-core cable for connection to the user’s control system.
Color codes and wiring connections are shown in Table 6. Typical wiring diagrams for connection to resistive
and reactive loads are shown in Figure 2.
Wire Color Function

Red + DC Input 13 – 28 VDC
Black - DC Input (Ground)
Green Load Input
White Load Ground
Table 6: Wiring Diagram for 100 Series Flow Switch

with transistor output
Figure 2: Connecting Resistive & Reactive Loads

Section 6: Setting the Trip Point
• The trip point should be at least 10% below the normal operating flow rate.
• Avoid selecting a flow switch where your normal flow will be in the bottom 20% of the range, forcing
you to set the trip point close to both the normal flow rate and the bottom of the range.
The trip point may be set prior to shipment at the factory if a Model 970 Preset Charge is ordered and a
trip point specified. The trip point is set to be accurate on falling flow of water unless you specify rising
flow.
User adjustment
The trip point is adjusted with a 20-turn potentiometer accessible from the in the
back of the electronics enclosure.
1. Remove the replaceable yellow label that covers the potentiometer hole.
2. Insert inserting a small screwdriver through the hole in the back of the
electronics case.
Turning the potentiometer clockwise will lower the trip point.
Turning the potentiometer counterclockwise will raise the trip point.
3. To set the trip point, install the flow switch in your actual circuit or on to your calibration bench.
If you are using a separate calibration bench, make sure you use the same style of inlet
fitting as you will use on your actual installation!
4. Adjust the actual fluid flow rate to the minimum acceptable flow rate.
Ensure that the flow rate is steady and that all air has been purged from the flow line.
5. Connect an ohmmeter or continuity meter between the black (common) and red (normally open NO)
or green (normally closed NC) wires in the output cable.
6. Adjust the potentiometer until the meter indicates the relay has tripped.
For the NO connection, the contacts will open, indicated by the measured resistance
changing form 0 ohms to infinite resistance.
For the NC connection, the contacts will close, indicated by the measured resistance
changing from infinite resistance to 0 ohms.
• There is a small time delay between when the trip point is crossed and when the relay trips.
The adjustment should be made slowly to avoid overshooting.
Note:
The actual trip point flow is different for rising and falling flows.
For applications in which an exact setting is required, be sure to test the trip point by reducing
flow through the trip point or increasing flow to rise through the trip point as required by your
particular application.

Section 7: Maintenance
Maintenance of the sensor is normally limited to cleaning the chamber in which the rotor spins and annual
recalibration.
The frequency of cleaning will vary with the type of fluid being run and the cleanliness of that fluid.
In most cases, annual cleaning immediately prior to recalibration is sufficient.
Cleaning the 100 Series Flow Switch
1. Turn OFF the liquid flow in your flow

circuit and remove the flow sensor or
transducer sensor from your system.
Place the unit on a clean surface.
2. Remove the 6 screws securing the

faceplate.
3. Remove the faceplate from the flow meter.
4. Remove the rotor and stainless steel shaft

from the flow cavity.
Remove the O-ring from the faceplate

Cleaning the 100 Series Flow Switch

5. Using a soft cloth dampened with water, alcohol or a light detergent solution, clean debris and dirt
from the rotor, the stainless steel shaft, the inside surfaces of faceplate and the surfaces of the flow
cavity
6. Inspect the bearing surface of the rotor.
If the bearing surface is worn or not round, replace the rotor.
Inspect the stainless steel shaft.

If the shaft shows signs of scoring or other wear, replace the shaft or the whole faceplate assembly.
7. Inspect the O-ring to ensure that it is not

brittle, cracked or otherwise damaged.
If necessary replace with a #132 O-ring of a

material compatible with the liquid being
passed through the flow meter.
Position the O-ring on the inner rim of the

faceplate.
8. Place the rotor in the flow cavity.
Position the shaft (or the faceplate) to locate

the shaft in the rotor.
9. Position the faceplate so that the holes

in the faceplate are aligned with the screw
holes in the front of the flow sensor body.
Replace the 6 securing screws.
Tighten the screws to a torque of 10 in-lbs

(hand tighten with a normal screwdriver).
11. Install the flow switch in your system.

Turn on liquid flow and check for leaks at the faceplate and connecting ports.
Tighten all connections as required to eliminate leaks.

Section 8: General
Trademarks
Celcon, Nylon and Kynar are registered trademarks of Celanese Plastics, DuPont and Elf-Autochem. Real-
Tuff, Hercules, Loctite and SWAK are trademarks of their respective holders.
Section 9: Reference Documents
Circuit Diagrams
WARNING NOTE
These diagrams are provided as reference information. We recommend that you do NOT attempt to repair a
flow switch circuit board, as generally the equipment or process being protected by the flow switch has a
much higher value than a replacement set of electronics or a replacement flow switch!
Replacement mechanical and electrical subsystems for 100 Series Flow Switches are accessible from our
website at www.proteusind.com



OM-244 023A 2011−03
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding

Flux Cored (FCAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)

Cutting and Gouging
Description
Engine Driven Welding Generator
Big Blue 800

®
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 Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
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 Quality System Warranty and service information for your
Standard. particular model are also provided.
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 2009−09
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. Hydraulic Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-7. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-8. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-9. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-4. Dangers liés à l’hydraulique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-5. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 13
2-7. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-8. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-9. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-2. Sound Level Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-4. Stick And MIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-5. DC TIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-6. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-7. Generator AC Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-2. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-4. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-6. Installing Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-7. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-8. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-9. Using The Optional Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-10. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-11. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-12. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-13. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-14. Connections To Terminal Strip T10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-1. Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-2. Description Of Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-4. Using Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-5. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-1. Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TABLE OF CONTENTS
SECTION 8 − ENGINE/GENERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-2. Engine Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-3. Operating Optional Oil Pan Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-5. Inspecting/Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-6. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-7. Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-8. Servicing Engine Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8-9. Engine/Generator Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SECTION 11 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
WARRANTY
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2010−03
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.
1-2. Arc Welding Hazards

Always verify the supply ground — check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you
disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions
grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-8. Read and tor first − double-check connections.
follow all Safety Standards. Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and Frequently inspect input power cord for damage or bare wiring —
repair this unit. replace cord immediately if damaged — bare wiring can kill.
Turn off all equipment when not in use.
During operation, keep everybody, especially children, away. Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
ELECTRIC SHOCK can kill. If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Touching live electrical parts can cause fatal shocks or
Do not touch electrode if you are in contact with the work, ground,
severe burns. The electrode and work circuit is
or another electrode from a different machine.
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also live Use only well-maintained equipment. Repair or replace damaged
when power is on. In semiautomatic or automatic wire parts at once. Maintain unit according to manual.
welding, the wire, wire reel, drive roll housing, and all Do not touch electrode holders connected to two welding ma-
metal parts touching the welding wire are electrically chines at the same time since double open-circuit voltage will be
live. Incorrectly installed or improperly grounded present.
equipment is a hazard. Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Do not touch live electrical parts.
Clamp work cable with good metal-to-metal contact to workpiece
Wear dry, hole-free insulating gloves and body protection. or worktable as near the weld as practical.
Insulate yourself from work and ground using dry insulating mats Insulate work clamp when not connected to workpiece to prevent
or covers big enough to prevent any physical contact with the work contact with any metal object.
or ground. Do not connect more than one electrode or work cable to any
Do not use AC output in damp areas, if movement is confined, or if single weld output terminal.
there is a danger of falling. SIGNIFICANT DC VOLTAGE exists in inverter power
Use AC output ONLY if required for the welding process. sources AFTER stopping engine.
Stop engine on inverter and discharge input capacitors according
If AC output is required, use remote output control if present on to instructions in Maintenance Section before touching any parts.
unit.
Additional safety precautions are required when any of the follow- HOT PARTS can burn.
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such Do not touch hot parts bare handed.
as floors, gratings, or scaffolds; when in cramped positions such Allow cooling period before working on equip-
as sitting, kneeling, or lying; or when there is a high risk of unavoid- ment.
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a To handle hot parts, use proper tools and/or wear heavy, insu-
semiautomatic DC constant voltage (wire) welder, 2) a DC manual lated welding gloves and clothing to prevent burns.
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder FLYING METAL or DIRT can injure eyes.
is recommended. And, do not work alone!
Disconnect input power or stop engine before installing or Welding, chipping, wire brushing, and grinding
servicing this equipment. Lockout/tagout input power according to cause sparks and flying metal. As welds cool,
OSHA 29 CFR 1910.147 (see Safety Standards). they can throw off slag.
Properly install and ground this equipment according to its Wear approved safety glasses with side shields even under your
Owner’s Manual and national, state, and local codes. welding helmet.
OM-244 023 Page 1

Do not weld on closed containers such as tanks, drums, or pipes,
FUMES AND GASES can be hazardous. unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Welding produces fumes and gases. Breathing these Do not weld where the atmosphere may contain flammable dust,
fumes and gases can be hazardous to your health. gas, or liquid vapors (such as gasoline).
Keep your head out of the fumes. Do not breathe the fumes. Connect work cable to the work as close to the welding area as
If inside, ventilate the area and/or use local forced ventilation at the practical to prevent welding current from traveling long, possibly
arc to remove welding fumes and gases. unknown paths and causing electric shock, sparks, and fire haz-
ards.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs) Do not use welder to thaw frozen pipes.
and the manufacturer’s instructions for metals, consumables, Remove stick electrode from holder or cut off welding wire at
coatings, cleaners, and degreasers. contact tip when not in use.
Work in a confined space only if it is well ventilated, or while Wear oil-free protective garments such as leather gloves, heavy
wearing an air-supplied respirator. Always have a trained watch- shirt, cuffless trousers, high shoes, and a cap.
person nearby. Welding fumes and gases can displace air and Remove any combustibles, such as a butane lighter or matches,
lower the oxygen level causing injury or death. Be sure the breath- from your person before doing any welding.
ing air is safe.
After completion of work, inspect area to ensure it is free of sparks,
Do not weld in locations near degreasing, cleaning, or spraying op- glowing embers, and flames.
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases. Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
area, the area is well ventilated, and while wearing an air-supplied for hot work and have a fire watcher and extinguisher nearby.
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded. NOISE can damage hearing.
BUILDUP OF GAS can injure or kill. Noise from some processes or equipment can dam-
age hearing.
Shut off shielding gas supply when not in use.
Wear approved ear protection if noise level is
Always ventilate confined spaces or use ap- high.
proved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
ARC RAYS can burn eyes and skin.
Wearers of Pacemakers and other Implanted
Arc rays from the welding process produce intense Medical Devices should keep away.
visible and invisible (ultraviolet and infrared) rays that
Implanted Medical Device wearers should consult their doctor
can burn eyes and skin. Sparks fly off from the weld.
and the device manufacturer before going near arc welding, spot
Wear an approved welding helmet fitted with a proper shade of filter welding, gouging, plasma arc cutting, or induction heating
lenses to protect your face and eyes from arc rays and sparks operations.
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards). CYLINDERS can explode if damaged.
Wear approved safety glasses with side shields under your
helmet. Shielding gas cylinders contain gas under high pres-
Use protective screens or barriers to protect others from flash, sure. If damaged, a cylinder can explode. Since gas
glare, and sparks; warn others not to watch the arc. cylinders are normally part of the welding process, be
Wear protective clothing made from durable, flame-resistant mate- sure to treat them carefully.
rial (leather, heavy cotton, or wool) and foot protection. Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
WELDING can cause fire or explosion. Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Welding on closed containers, such as tanks, drums, Keep cylinders away from any welding or other electrical circuits.
or pipes, can cause them to blow up. Sparks can fly off Never drape a welding torch over a gas cylinder.
from the welding arc. The flying sparks, hot workpiece, Never allow a welding electrode to touch any cylinder.
and hot equipment can cause fires and burns. Accidental contact of
electrode to metal objects can cause sparks, explosion, overheating, Never weld on a pressurized cylinder — explosion will result.
or fire. Check and be sure the area is safe before doing any welding. Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
Remove all flammables within 35 ft (10.7 m) of the welding arc. If associated parts in good condition.
this is not possible, tightly cover them with approved covers.
Turn face away from valve outlet when opening cylinder valve.
Do not weld where flying sparks can strike flammable material.
Keep protective cap in place over valve except when cylinder is in
Protect yourself and others from flying sparks and hot metal. use or connected for use.
Be alert that welding sparks and hot materials from welding can Use the right equipment, correct procedures, and sufficient num-
easily go through small cracks and openings to adjacent areas. ber of persons to lift and move cylinders.
Watch for fire, and keep a fire extinguisher nearby. Read and follow instructions on compressed gas cylinders,
Be aware that welding on a ceiling, floor, bulkhead, or partition can associated equipment, and Compressed Gas Association (CGA)
cause fire on the hidden side. publication P-1 listed in Safety Standards.
OM-244 023 Page 2

1-3. Engine Hazards
BATTERY EXPLOSION can injure. EXHAUST SPARKS can cause fire.

Always wear a face shield, rubber gloves, and Do not let engine exhaust sparks cause fire.
protective clothing when working on a battery. Use approved engine exhaust spark arrestor in
Stop engine before disconnecting or connect- required areas — see applicable codes.
ing battery cables, battery charging cables (if
applicable), or servicing battery. HOT PARTS can burn.
Do not allow tools to cause sparks when working on a battery.
Do not touch hot parts bare handed.
Do not use welder to charge batteries or jump start vehicles un-
Allow cooling period before working on equip-
less the unit has a battery charging feature designed for this pur-
ment.
pose.
To handle hot parts, use proper tools and/or
Observe correct polarity (+ and −) on batteries. wear heavy, insulated welding gloves and
Disconnect negative (−) cable first and connect it last. clothing to prevent burns.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during STEAM AND HOT COOLANT can burn.
normal operation and when being charged.
If possible, check coolant level when engine is
Follow battery manufacturer’s instructions when working on or cold to avoid scalding.
near a battery.
Always check coolant level at overflow tank, if
BATTERY CHARGING OUTPUT can injure. present on unit, instead of radiator (unless told
(Battery charging feature not present on all models.) otherwise in maintenance section or engine
Have only qualified persons do battery charging work. manual).
If the engine is warm, checking is needed, and there is no over-
Charge lead-acid batteries only. Do not use battery charger to
flow tank, follow the next two statements.
supply power to an extra-low-voltage electrical system or to
charge dry cell batteries. Wear safety glasses and gloves and put a rag over radiator cap.
Do not charge a frozen battery. Turn cap slightly and let pressure escape slowly before
Do not use damaged charging cables. completely removing cap.
Do not charge a battery that has loose terminals or one showing Using a generator indoors CAN KILL
damage such as a cracked case or cover. YOU IN MINUTES.
Before charging battery, select correct charger voltage to match
battery voltage. Generator exhaust contains carbon monoxide.
Set battery charging controls to the Off position before connect- This is a poison you cannot see or smell.
ing to battery. Do not allow battery charging clips to touch each NEVER use inside a home or garage, EVEN IF
other. doors and windows are open.
Keep charging cables away from vehicle hood, door, or moving Only use OUTSIDE and far away from windows, doors, and
parts. vents.
FUEL can cause fire or explosion. BATTERY ACID can BURN SKIN and EYES.
Stop engine and let it cool off before checking or Do not tip battery.
adding fuel. Replace damaged battery.
Do not add fuel while smoking or if unit is near Flush eyes and skin immediately with water.
any sparks or open flames.
ENGINE HEAT can cause fire.
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine. Do not locate unit on, over, or near combustible
Dispose of rags in a fireproof container. surfaces or flammables.
Always keep nozzle in contact with tank when fueling. Keep exhaust and exhaust pipes way from
flammables.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
OM-244 023 Page 3

1-4. Hydraulic Hazards
HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics
HYDRAULIC EQUIPMENT can injure near sparks or flames; do not smoke near hydraulic fluid.
or kill.
Incorrect installation or operation of this unit finished and before starting unit.
could result in equipment failure and personal
injury. Only qualified persons should install, op- If ANY fluid is injected into the skin, it must be surgically removed
erate, and service this unit according to its within a few hours by a doctor familiar with this type of injury or gan-
Owner’s Manual, industry standards, and na- grene may result.
tional, state, and local codes.
Do not exceed the rated output or capacity of the hydraulic pump MOVING PARTS can injure.
or any equipment in the hydraulic system. Design hydraulic sys-
tem so failure of any hydraulic component will not put people or Keep away from moving parts such as fans,
property at risk. belts and rotors.
Before working on hydraulic system, turn off and lockout/tagout Keep all doors, panels, covers, and guards
unit, release pressure, and be sure hydraulic pressure cannot be closed and securely in place.
accidentally applied.
Do not work on hydraulic system with unit running unless you are Keep hands, hair, loose clothing, and tools away from moving
a qualified person and following the manufacturer’s instructions. parts.
Do not modify or alter hydraulic pump or manufacturer-supplied Before working on hydraulic system, turn off and lockout/tagout
equipment. Do not disconnect, disable, or override any safety unit, release pressure, and be sure hydraulic pressure cannot be
equipment in the hydraulic system. accidentally applied.
Use only components/accessories approved by the manufac- Have only qualified people remove guards or covers for maint-
turer. enance and troubleshooting as necessary.
Keep away from potential pinch points or crush points created by Reinstall doors, panels, covers, or guards when servicing is
equipment connected to the hydraulic system. finished and before starting engine.
Do not work under or around any equipment that is supported
only by hydraulic pressure. Properly support equipment by
mechanical means. HOT PARTS AND FLUID can burn.
Do not touch hot parts bare handed or allow hot

fluid to contact skin.
ment.
HYDRAULIC FLUID can injure or kill.
To handle hot parts, use proper tools and/or wear heavy, insu-
Before working on hydraulic system, turn off and lated welding gloves and clothing to prevent burns.
lockout/tagout unit, release pressure, and be sure
hydraulic pressure cannot be accidentally applied.
Relieve pressure before disconnecting or con-
necting hydraulic lines. READ INSTRUCTIONS.
Check hydraulic system components and all con- Read and follow all labels and the Owner’s
nections and hoses for damage, leaks, and wear Manual carefully before installing, operating, or
before operating unit. servicing unit. Read the safety information at
Wear protective equipment such as safety the beginning of the manual and in each
glasses, leather gloves, heavy shirt and trousers, section.
high shoes, and a cap when working on hydraulic
Use only genuine replacement parts from the manufacturer.
system.
Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
Use a piece of paper or cardboard to search for leaks−−never use codes.
bare hands. Do not use equipment if leaks are found.
1-5. Compressed Air Hazards
COMPRESSED AIR EQUIPMENT can Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s in-
injure or kill.
structions.
Incorrect installation or operation of this unit
could result in equipment failure and personal Do not modify or alter compressor or manufacturer-supplied
injury. Only qualified persons should install, op- equipment. Do not disconnect, disable, or override any safety
erate, and service this unit according to its equipment in the compressed air system.
Owner’s Manual, industry standards, and na-
tional, state, and local codes. Use only components and accessories approved by the manufac-
turer.
Do not exceed the rated output or capacity of the compressor or
any equipment in the compressed air system. Design compressed Keep away from potential pinch points or crush points created by
air system so failure of any component will not put people or prop- equipment connected to the compressed air system.
erty at risk.
Before working on compressed air system, turn off and lockout/ Do not work under or around any equipment that is supported only
tagout unit, release pressure, and be sure air pressure cannot be by air pressure. Properly support equipment by mechanical
accidentally applied. means.
OM-244 023 Page 4
HOT METAL from air arc cutting and MOVING PARTS can injure.
gouging can cause fire or explosion.
Keep away from moving parts such as fans,
Do not cut or gouge near flammables. belts and rotors.
Watch for fire; keep extinguisher nearby. Keep all doors, panels, covers, and guards
closed and securely in place.
Keep hands, hair, loose clothing, and tools away from moving
COMPRESSED AIR can injure or kill. parts.
Before working on compressed air system, turn off and lockout/
Before working on compressed air system,
tagout unit, release pressure, and be sure air pressure cannot be
turn off and lockout/tagout unit, release pres-
accidentally applied.
sure, and be sure air pressure cannot be acci-
dentally applied. Have only qualified people remove guards or covers for maint-
Relieve pressure before disconnecting or con- enance and troubleshooting as necessary.
necting air lines. Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
Do not direct air stream toward self or others.
Wear protective equipment such as safety glasses, hearing pro-
tection, leather gloves, heavy shirt and trousers, high shoes, and HOT PARTS can burn.
a cap when working on compressed air system.
Do not touch hot compressor or air system
Use soapy water or an ultrasonic detector to search for parts.
leaks−−never use bare hands. Do not use equipment if leaks are
found.
ment.
To handle hot parts, use proper tools and/or wear heavy, insu-
finished and before starting unit.
lated welding gloves and clothing to prevent burns.
If ANY air is injected into the skin or body seek medical help im-
mediately.
BREATHING COMPRESSED AIR can in-

jure or kill. READ INSTRUCTIONS.
Do not use compressed air for breathing. Read and follow all labels and the Owner’s
Use only for cutting, gouging, and tools. Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
TRAPPED AIR PRESSURE AND WHIPPING section.
HOSES can injure. Use only genuine replacement parts from the manufacturer.
Release air pressure from tools and system be- Perform maintenance and service according to the Owner’s
fore servicing, adding or changing attach- Manuals, industry standards, and national, state, and local
ments, or opening compressor oil drain or oil fill codes.
cap.
1-6. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard. OVERHEATING can damage motors.

Do not install or place unit on, over, or near Turn off or unplug equipment before starting or
combustible surfaces. stopping engine.
Do not install unit near flammables. Do not let low voltage and frequency caused by
Do not overload building wiring − be sure power supply system is low engine speed damage electric motors.
properly sized, rated, and protected to handle this unit. Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit and properly installed FLYING SPARKS can injure.
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see Wear a face shield to protect eyes and face.
Specifications). Shape tungsten electrode only on grinder with
Use equipment of adequate capacity to lift and proper guards in a safe location wearing proper
support unit. face, hand, and body protection.
If using lift forks to move unit, be sure forks are long enough to Sparks can cause fires — keep flammables away.
extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles MOVING PARTS can injure.
when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised Keep away from moving parts.
NIOSH Lifting Equation (Publication No. 94−110) when manu- Keep away from pinch points such as drive
ally lifting heavy parts or equipment. rolls.
OM-244 023 Page 5

WELDING WIRE can injure. H.F. RADIATION can cause interference.
Do not press gun trigger until instructed to do High-frequency (H.F.) can interfere with radio
so. navigation, safety services, computers, and
Do not point gun toward any part of the body, communications equipment.
other people, or any metal when threading Have only qualified persons familiar with
welding wire. electronic equipment perform this installation.
The user is responsible for having a qualified electrician
OVERUSE can cause OVERHEATING. promptly correct any interference problem resulting from the
installation.
Allow cooling period; follow rated duty cycle. If notified by the FCC about interference, stop using the
Reduce current or reduce duty cycle before equipment at once.
starting to weld again. Have the installation regularly checked and maintained.
Do not block or filter airflow to unit. Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
TILTING OF TRAILER can injure.
Electromagnetic energy can interfere with
Use tongue jack or blocks to support weight. sensitive electronic equipment such as micro-
Properly install welding generator onto trailer processors, computers, and computer-driven
according to instructions supplied with trailer. equipment such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
READ INSTRUCTIONS. To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Read and follow all labels and the Owner’s Locate welding operation 100 meters from any sensitive elec-
Manual carefully before installing, operating, or tronic equipment.
servicing unit. Read the safety information at
Be sure this welding machine is installed and grounded
the beginning of the manual and in each
according to this manual.
section.
If interference still occurs, the user must take extra measures
Use only genuine replacement parts from the manufacturer.
such as moving the welding machine, using shielded cables,
Perform maintenance and service according to the Owner’s using line filters, or shielding the work area.
Manuals, industry standards, and national, state, and local
codes.
1-7. California Proposition 65 Warnings

For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other Diesel engine exhaust and some of its constituents are
reproductive harm. Wash hands after handling. known to the State of California to cause cancer, birth
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
OM-244 023 Page 6

1-8. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
from Global Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org).
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, from National Fire Protection Association,
and Cutting, American Welding Society Standard AWS F4.1, from Glob- Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
al Engineering Documents (phone: 1-877-413-5184, website: For Standards about hydraulic systems, contact the National Fluid
www.global.ihs.com). Power Association, Publications Department, 3333 North Mayfair
National Electrical Code, NFPA Standard 70, from National Fire Protec- Road, Suite 211, Milwaukee, WI 53222-3219 (phone: (414) 778-3344,
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: website: www.nfpa.com).
www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Indus-
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
from Compressed Gas Association, 4221 Walney Road, 5th Floor, and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
Safety in Welding, Cutting, and Allied Processes, CSA Standard (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
W117.2, from Canadian Standards Association, Standards Sales, 5060 phone for Region 5, Chicago, is 312-353-2220, website:
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: www.osha.gov).
800-463-6727, website: www.csa-international.org). U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
Standards Association, Standards Sales, 5060 Spectrum Way, Suite www.cpsc.gov).
100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: Applications Manual for the Revised NIOSH Lifting Equation, The Na-
www.csa-international.org). tional Institute for Occupational Safety and Health (NIOSH), 1600
Safe Practice For Occupational And Educational Eye And Face Protec- Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
tion, ANSI Standard Z87.1, from American National Standards Institute, www.cdc.gov/NIOSH).
1-9. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). Welding current creates an EMF field welding circuit as possible.
around the welding circuit and welding equipment. EMF fields may inter-
fere with some medical implants, e.g. pacemakers. Protective 5. Connect work clamp to workpiece as close to the weld as
measures for persons wearing medical implants have to be taken. For possible.
example, access restrictions for passers−by or individual risk assess-
ment for welders. All welders should use the following procedures in 6. Do not work next to, sit or lean on the welding power source.
order to minimize exposure to EMF fields from the welding circuit:
7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
cable cover. About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.
OM-244 023 Page 7

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
fre_rom_2010−03
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
NOTE − Indique des déclarations pas en relation avec des blessures
afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.
2-2. Dangers relatifs au soudage à l’arc

à souder manuel (électrode enrobée) DC, 3) un poste à souder
Les symboles présentés ci-après sont utilisés tout au long du manuel AC avec tension à vide réduite. Dans la plupart des cas, un
présent manuel pour attirer votre attention et identifier les ris- poste courant continu de type CV est recommandé. Et, ne pas tra-
ques de danger. Lorsque vous voyez un symbole, soyez vailler seul!
vigilant et suivez les directives mentionnées afin d’éviter tout
Couper l’alimentation ou arrêter le moteur avant de procéder à
danger. Les consignes de sécurité présentées ci-après ne
l’installation, à la réparation ou à l’entretien de l’appareil.
font que résumer l’information contenue dans les normes de
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
sécurité énumérées à la section 1-8. Veuillez lire et respecter
1910.147 (voir normes de sécurité).
toutes ces normes de sécurité.
Installer et mettre à la terre correctement cet appareil conformé-
ment à son manuel d’utilisation et aux codes nationaux,
L’installation, l’utilisation, l’entretien et les réparations ne
provinciaux et municipaux.
doivent être confiés qu’à des personnes qualifiées.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
Au cours de l’utilisation, tenir toute personne à l’écart et plus
raccordé à la borne de terre du sectionneur ou que la fiche du
particulièrement les enfants.
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conduc-
UN CHOC ÉLECTRIQUE peut tuer. teur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
Un simple contact avec des pièces électriques peut protégez−les contre les étincelles et les pièces métalliques chau-
provoquer une électrocution ou des blessures grades.
ves. L’électrode et le circuit de soudage sont sous Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est
tension dès que l’appareil est sur ON. Le circuit pas endommagé ou dénudé − remplacer le cordon immédiatement
d’entrée et les circuits internes de l’appareil sont s’il est endommagé − un câble dénudé peut provoquer une électro-
également sous tension à ce moment-là. En soudage cution.
semi-automatique ou automatique, le fil, le dévidoir, le Mettre l’appareil hors tension quand on ne l’utilise pas.
logement des galets d’entraînement et les pièces Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
métalliques en contact avec le fil de soudage sont sante ou mal épissés.
sous tension. Des matériels mal installés ou mal mis Ne pas enrouler les câbles autour du corps.
à la terre présentent un danger.
Si la pièce soudée doit être mise à la terre, le faire directement
Ne jamais toucher les pièces électriques sous tension. avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
câble de retour.
Porter des gants et des vêtements de protection secs ne compor-
tant pas de trous. Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres Ne pas toucher des porte électrodes connectés à deux machines
moyens isolants suffisamment grands pour empêcher le contact en même temps à cause de la présence d’une tension à vide dou-
physique éventuel avec la pièce ou la terre. blée.
Ne pas se servir de source électrique à courant électrique dans les N’utiliser qu’un matériel en bon état. Réparer ou remplacer
zones humides, dans les endroits confinés ou là où on risque de sur-le-champ les pièces endommagées. Entretenir l’appareil
tomber. conformément à ce manuel.
Se servir d’une source électrique à courant électrique UNIQUE- Porter un harnais de sécurité quand on travaille en hauteur.
MENT si le procédé de soudage le demande. Maintenir solidement en place tous les panneaux et capots.
Si l’utilisation d’une source électrique à courant électrique s’avère Fixer le câble de retour de façon à obtenir un bon contact métal-
nécessaire, se servir de la fonction de télécommande si l’appareil métal avec la pièce à souder ou la table de travail, le plus près pos-
en est équipé. sible de la soudure.
Des précautions de sécurité supplémentaires sont requises dans Isoler la pince de masse quand pas mis à la pièce pour éviter le
des environnements à risque comme: les endroits humides ou contact avec tout objet métallique.
lorsque l’on porte des vêtements mouillés; sur des structures mé-
Il reste une TENSION DC NON NÉGLIGEABLE dans les
talliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important sources de soudage onduleur UNE FOIS le moteur coupé.
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser Couper l’alimentation du poste et décharger les condensateurs
les appareils suivants dans l’ordre de préférence: 1) un poste à d’entrée comme indiqué dans la Section Maintenance avant de
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste toucher des composants.
OM-244 023 Page 8
LES PIÈCES CHAUDES peuvent Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
provoquer des brûlures. et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
Ne pas toucher à mains nues les parties chau- et Z87.1 énuméré dans les normes de sécurité).
des. Porter des lunettes de sécurité avec écrans latéraux même sous
Prévoir une période de refroidissement avant votre casque.
de travailler à l’équipement. Avoir recours à des écrans protecteurs ou à des rideaux pour
Ne pas toucher aux pièces chaudes, utiliser les outils recomman- protéger les autres contre les rayonnements les éblouissements
dés et porter des gants de soudage et des vêtements épais pour et les étincelles ; prévenir toute personne sur les lieux de ne pas
éviter les brûlures. regarder l’arc.
Porter des vêtements confectionnés avec des matières résistan-
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
DES PIECES DE METAL ou DES LE SOUDAGE peut provoquer un
SALETES peuvent provoquer incendie ou une explosion.
des blessures dans les yeux.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
Le soudage, l’écaillement, le passage de la pièce à la brosse en
provoquer leur éclatement. Des étincelles peuvent
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des être projetées de l’arc de soudure. La projection d’étincelles, des
soudures, elles risquent de projeter du laitier. pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
Porter des lunettes de sécurité avec écrans latéraux ou un écran des objets métalliques peut provoquer des étincelles, une explosion,
facial. un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
LES FUMÉES ET LES GAZ peu-
Déplacer toutes les substances inflammables à une distance de
vent être dangereux. 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
Le soudage génère des fumées et des gaz. Leur soigneusement avec des protections homologués.
inhalation peut être dangereux pour votre santé. Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Eloigner votre tête des fumées. Ne pas respirer les fumées. Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
Si la ventilation est médiocre, porter un respirateur anti-vapeurs fissures et des ouvertures.
approuvé.
Surveiller tout déclenchement d’incendie et tenir un extincteur à
Lire et comprendre les spécifications de sécurité des matériaux proximité.
(MSDS) et les instructions du fabricant concernant les métaux, les Le soudage effectué sur un plafond, plancher, paroi ou séparation
consommables, les revêtements, les nettoyants et les dégraisseurs. peut déclencher un incendie de l’autre côté.
Travailler dans un espace fermé seulement s’il est bien ventilé ou Ne pas effectuer le soudage sur des conteneurs fermés tels que
en portant un respirateur à alimentation d’air. Demander toujours à des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
un surveillant dûment formé de se tenir à proximité. Des fumées et préparés correctement conformément à AWS F4.1 (voir les nor-
des gaz de soudage peuvent déplacer l’air et abaisser le niveau mes de sécurité).
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger. Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
peurs inflammables (vapeur d’essence, par exemple).
Ne pas souder dans des endroits situés à proximité d’opérations
Brancher le câble de masse sur la pièce le plus près possible de la
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
zone de soudage pour éviter le transport du courant sur une
les rayons de l’arc peuvent réagir en présence de vapeurs et for-
longue distance par des chemins inconnus éventuels en provo-
mer des gaz hautement toxiques et irritants.
quant des risques d’électrocution, d’étincelles et d’incendie.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
galvanisé, plaqué en plomb ou au cadmium à moins que le revête- lées.
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les En cas de non utilisation, enlever la baguette d’électrode du porte-
revêtements et tous les métaux renfermant ces éléments peuvent électrode ou couper le fil à la pointe de contact.
dégager des fumées toxiques en cas de soudage. Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
LES ACCUMULATIONS DE GAZ revers, des chaussures hautes et un couvre chef.
risquent de provoquer des blessures Avant de souder, retirer toute substance combustible de vos po-
ou même la mort. ches telles qu’un allumeur au butane ou des allumettes.
Fermer l’alimentation du gaz protecteur en cas Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-
de non utilisation. ce d’étincelles incandescentes ni de flammes.
Veiller toujours à bien aérer les espaces confinés ou se servir Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
d’un respirateur d’adduction d’air homologué. Ne pas augmenter leur puissance; ne pas les ponter.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
LES RAYONS DE L’ARC peuvent extincteur à proximité.
provoquer des brûlures dans les
yeux et sur la peau. LE BRUIT peut affecter l’ouïe.
Le rayonnement de l’arc du procédé de soudage
Le bruit des processus et des équipements peut
génère des rayons visibles et invisibles intenses
affecter l’ouïe.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le Porter des protections approuvés pour les
soudage. oreilles si le niveau sonore est trop élevé.
OM-244 023 Page 9

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
peuvent affecter les implants médicaux. de se renverser.
Les porteurs de stimulateurs cardiaques et Tenir les bouteilles éloignées des circuits de soudage ou autres
autres implants médicaux doivent rester à circuits électriques.
distance. Ne jamais placer une torche de soudage sur une bouteille à gaz.
Les porteurs d’implants médicaux doivent consulter leur Une électrode de soudage ne doit jamais entrer en contact avec
médecin et le fabricant du dispositif avant de s’approcher de la une bouteille.
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage Ne jamais souder une bouteille pressurisée − risque d’explosion.
par induction. Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Si des BOUTEILLES sont endomma- Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
gées, elles pourront exploser. bouteille.
Des bouteilles de gaz protecteur contiennent du gaz Maintenir le chapeau de protection sur la soupape, sauf en cas
sous haute pression. Si une bouteille est endomma- d’utilisation ou de branchement de la bouteille.
gée, elle peut exploser. Du fait que les bouteilles de gaz font Utiliser les équipements corrects, les bonnes procédures et suffi-
normalement partie du procédé de soudage, les manipuler avec samment de personnes pour soulever et déplacer les bouteilles.
précaution.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, l’équipement connexe et le dépliant P-1 de la CGA (Compressed
des chocs mécaniques, des dommages physiques, du laitier, des Gas Association) mentionné dans les principales normes de sécu-
flammes ouvertes, des étincelles et des arcs. rité.
2-3. Dangers existant en relation avec le moteur

Ranger les câbles de charge à distance du capot, des portes et
L’EXPLOSION DE LA BATTERIE des pièces mobiles du véhicule.
peut provoquer des blessures.
Toujours porter une protection faciale, des LE CARBURANT MOTEUR peut pro-
gants en caoutchouc et vêtements de protec- voquer un incendie ou une explosion.
tion lors d’une intervention sur la batterie.
Arrêter le moteur avant de vérifier le niveau de
Arrêter le moteur avant de débrancher ou de brancher des câbles carburant ou de faire le plein.
de batterie, des câbles de chargeur de batterie (le cas échéant) ou
Ne pas faire le plein en fumant ou proche d’une source d’étincel-
de batterie d’entretien.
les ou d’une flamme nue.
Eviter de provoquer des étincelles avec les outils en travaillant sur Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
la batterie. pour son expansion.
Ne pas utiliser l’appareil de soudage pour charger des batteries ou Faire attention de ne pas renverser de carburant. Nettoyer tout
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf carburant renversé avant de faire démarrer le moteur.
si l’appareil dispose d’une fonctionnalité de charge de batterie
destinée à cet usage. Jeter les chiffons dans un récipient ignifuge.
Toujours garder le pistolet en contact avec le réservoir lors du
Observer la polarité correcte (+ et −) sur les batteries.
remplissage.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
Les sources d’étincelles, flammes nues, cigarettes et autres Les PIÈCES MOBILES peuvent causer
sources d’inflammation doivent être maintenues à l’écart des des blessures.
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.
S’abstenir de toucher des parties mobiles telles
Respecter les consignes du fabricant de la batterie pour que des ventilateurs, courroies et rotors.
travailler sur une batterie ou à proximité.
Maintenir fermés et verrouillés les portes, panneaux,
Le COURANT DE CHARGE DE BATTERIE peut recouvrements et dispositifs de protection.
provoquer des blessures (la fonctionnalité de charge de
batterie n’est pas disponible sur tous les modèles). Arrêter le moteur avant d’installer ou brancher l’appareil.
Les opérations de charge de batterie ne doivent être effectuées Lorsque cela est nécessaire pour des travaux d entretien et de
que par des personnes qualifiées. dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
Ne charger que des batteries plomb−acide. Ne pas utiliser le
chargeur de batterie pour alimenter un autre circuit électrique Pour empêcher tout démarrage accidentel pendant les travaux
basse tension ou pour charger des batteries sèches. d’entretien, débrancher le câble négatif (−) de batterie de la borne.
Ne pas charger une batterie gelée. Ne pas approcher les mains, cheveux, vêtements lâches et outils
Ne pas utiliser de câbles de charge endommagés. des organes mobiles.
Ne pas charger une batterie dont les bornes sont desserrées ou Remettre en place les portes, panneaux, recouvrements ou
présentant une détérioration comme par exemple un boîtier ou un dispositifs de protection à la fin des travaux d’entretien et avant de
couvercle fissuré. mettre le moteur en marche.
Avant de charger une batterie, sélectionner la tension de charge
correspondant à la tension de la batterie. Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
mise en route accidentelle du moteur.
Régler les commandes de charge de batterie sur la position d’arrêt
avant de brancher la batterie. Veiller à ce que les pinces de charge Bloquer le volant moteur pour éviter sa rotation lors d’une
ne se touchent pas. intervention sur le générateur.
OM-244 023 Page 10
Mettre des lunettes de sécurité et des gants, placer un torchon sur
LES ÉTINCELLES À L’ÉCHAPPEMENT le bouchon du radiateur.
peuvent provoquer un incendie.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper
Empêcher les étincelles d’échappement du avant d’enlever le bouchon.
moteur de provoquer un incendie.
Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur. L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures. Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisi-
Ne pas toucher des parties chaudes à mains ble et inodore.
nues.
JAMAIS utiliser dans une maison ou garage,
Prévoir une période de refroidissement avant de même avec les portes et fenêtres ouvertes.
travailler à l’équipement.
Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
Ne pas toucher aux pièces chaudes, utiliser les outils recomman- bouches aération.
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
L’ACIDE DE LA BATTERIE peut pro-
LA VAPEUR ET LE LIQUIDE DE voquer des brûlures dans les YEUX et
REFROIDISSEMENT CHAUD peuvent sur la PEAU.
provoquer des brûlures. Ne pas renverser la batterie.
Il est préférable de vérifier le liquide de refroi- Remplacer une batterie endommagée.
dissement une fois le moteur refroidi pour éviter Rincer immédiatement les yeux et la peau à l’eau.
de se brûler.
LA CHALEUR DU MOTEUR peut pro-
Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si pré- voquer un incendie.
cisé autrement dans la section maintenance du manuel du Ne pas placer l’appareil sur, au-dessus ou à
moteur). proximité de surfaces inflammables.
Si le moteur est chaud et que le liquide doit être vérifié, opérer com- Tenir à distance les produits inflammables de l’échappement.
me suivant.
2-4. Dangers liés à l’hydraulique
Les ÉQUIPEMENTS HYDRAULIQUES Ne pas intervenir sous ou autour d’un équipement qui n’est
peuvent provoquer des blessures ou soutenu que par la pression hydraulique. Soutenir l’équipement
même la mort. de façon appropriée par un moyen mécanique.
Une installation ou une utilisation incorrecte

de cet appareil pourrait conduire à des dégâts Le LIQUIDE HYDRAULIQUE risque de
matériels ou corporels. Seul un personnel provoquer des blessures ou même la mort.
qualifié est autorisé à installer, faire fonctionner
et réparer cet appareil conformément à son Avant d’intervenir sur le circuit hydraulique,
manuel d’utilisation, aux normes industrielles couper l’alimentation électrique, verrouiller
et aux codes nationaux, d’état ou locaux. et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit hydraulique ne peut
être remis sous pression par inadvertance.
Ne pas dépasser le débit nominal ou la capacité de la pompe Détendre la pression avant de débrancher ou
hydraulique ou de tout équipement du circuit hydraulique. de brancher des canalisations hydrauliques.
Concevoir le circuit hydraulique de telle sorte que la défaillance Avant d’utiliser l’appareil, contrôler
d’un composant hydraulique ne risque pas de provoquer les composants du circuit hydraulique,
un accident matériel ou corporel. les branchements et les flexibles en recherchant
tout signe de détérioration, de fuite et d’usure.
Avant d’intervenir sur le circuit hydraulique, couper l’alimentation
électrique, verrouiller et étiqueter l’appareil, détendre la pression Pour intervenir sur un circuit hydraulique, porter un équipement
et s’assurer que le circuit hydraulique ne peut être remis sous de protection tel que des lunettes de sécurité, des gants de cuir,
pression par inadvertance. une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
Ne pas intervenir sur le circuit hydraulique lorsque l’appareil
fonctionne. Seul un personnel qualifié et appliquant les consignes Pour rechercher des fuites, utiliser un morceau de papier ou
du fabricant est autorisé le faire. de carton, jamais les mains nues. En cas de détection de fuite,
ne pas utiliser l’équipement.
Ne pas modifier ou altérer la pompe hydraulique ou
les équipements fournis par le fabricant. Ne pas débrancher, Le LIQUIDE HYDRAULIQUE est INFLAMMABLE. Ne pas
désactiver ou neutraliser les équipements de sécurité du circuit intervenir sur des composants hydrauliques à proximité
hydraulique. d’étincelles ou de flammes; ne pas fumer à proximité de liquide
hydraulique.
Utiliser uniquement des composants et accessoires homologués Remettre les portes, panneaux, recouvrements ou dispositifs
par le fabricant. de protection quand l’entretien est terminé et avant de mettre
Se tenir à l’écart de tout point présentant un danger de pincement en marche l’appareil.
ou d’écrasement créé par l’équipement raccordé au circuit En cas de pénétration d’un QUELCONQUE liquide dans la peau,
hydraulique. celui−ci doit être retiré chirurgicalement sous quelques heures par
OM-244 023 Page 11
un médecin familiarisé avec ce type de blessure, faute de quoi
la gangrène pourrait apparaître. LES PIÈCES ET LIQUIDES CHAUDS
peuvent provoquer des brûlures.
Les PIÈCES MOBILES peuvent causer Ne pas toucher les pièces chaudes à main nue
des blessures. ni laisser des liquides chauds entrer en contact
avec la peau.
Prévoir une période de refroidissement avant d’intervenir
que des ventilateurs, courroies et rotors.
sur l’équipement.
Maintenir fermés et verrouillés les portes,
Ne pas toucher aux pièces chaudes, utiliser les outils
panneaux, recouvrements et dispositifs
recommandés et porter des gants de soudage et des vêtements
de protection.
épais pour éviter les brûlures.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
LIRE LES INSTRUCTIONS.
Avant d’intervenir sur le circuit hydraulique, couper l’alimentation
électrique, verrouiller et étiqueter l’appareil, détendre la pression Lire et appliquer les instructions sur les
et s’assurer que le circuit hydraulique ne peut être remis sous étiquettes et le Mode d’emploi avant
pression par inadvertance. l’installation, l’utilisation ou l’entretien de
Demander seulement à un personnel qualifié d’enlever l’appareil. Lire les informations de sécurité au
les dispositifs de sécurité ou les recouvrements pour effectuer, début du manuel et dans chaque section.
s’il y a lieu, des travaux d’entretien et de dépannage. N’utiliser que les pièces de rechange recommandées par le
Remettre en place les portes, panneaux, recouvrements ou constructeur.
dispositifs de protection à la fin des travaux d’entretien et avant Effectuer l’entretien en respectant les manuels d’utilisation,
de mettre le moteur en marche. les normes industrielles et les codes nationaux, d’état et locaux.
2-5. Dangers liés à l’air comprimé

Un ÉQUIPEMENT PNEUMATIQUE risque
L’AIR COMPRIMÉ risque de provoquer
de provoquer des blessures ou même
des blessures ou même la mort.
la mort.
Avant d’intervenir sur le circuit d’air comprimé,
Une installation ou une utilisation incorrecte de
couper l’alimentation électrique, verrouiller
cet appareil pourrait conduire à des dégâts
et étiqueter l’appareil, détendre la pression
matériels ou corporels. Seul un personnel
et s’assurer que le circuit d’air ne peut être mis
qualifié est autorisé à installer, utiliser et
sous pression par inadvertance.
entretenir cet appareil conformément à son
manuel d’utilisation, aux normes industrielles et Détendre la pression avant de débrancher ou
aux codes nationaux, d’état ou locaux. de brancher des canalisations d’air.
Ne pas dépasser le débit nominal ou la capacité du compresseur Avant d’utiliser l’appareil, contrôler
ou de tout équipement du circuit d’air comprimé. Concevoir les composants du circuit d’air comprimé,
le circuit d’air comprimé de telle sorte que la défaillance les branchements et les flexibles en
d’un composant ne risque pas de provoquer un accident recherchant tout signe de détérioration, de fuite
matériel ou corporel. et d’usure.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance. Ne pas diriger un jet d’air vers soi−même ou vers autrui.
Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil Pour intervenir sur un circuit d’air comprimé, porter un équipement
fonctionne. Seul un personnel qualifié est autorisé, et appliquant de protection tel que des lunettes de sécurité, des gants de cuir,
les consignes du fabricant. une chemise et un pantalon en tissu résistant, des chaussures
Ne pas modifier ou altérer le compresseur ou les équipements montantes et une coiffe.
fournis par le fabricant. Ne pas débrancher, désactiver ou
neutraliser les équipements de sécurité du circuit d’air Pour rechercher des fuites, utiliser de l’eau savonneuse ou
comprimé. un détecteur à ultrasons, jamais les mains nues. En cas
Utiliser uniquement des composants et accessoires de détection de fuite, ne pas utiliser l’équipement.
homologués par le fabricant.
Remettre les portes, panneaux, recouvrements ou dispositifs
Se tenir à l’écart de tout point présentant un danger de pincement de protection quand l’entretien est terminé et avant de mettre
ou d’écrasement créé par l’équipement raccordé au circuit d’air en marche l’appareil.
comprimé.
Ne pas intervenir sous ou autour d’un équipement qui n’est En cas d’injection d’air dans la peau ou le corps, demander
soutenu que par la pression pneumatique. Soutenir l’équipement immédiatement une assistance médicale.
de façon appropriée par un moyen mécanique.
L’INHALATION D’AIR COMPRIMÉ risque

MÉTAL CHAUD provenant du décou- de provoquer des blessures ou même
page ou du gougeage à l’arc risque de la mort.
provoquer un incendie ou une explo-
sion. Ne pas inhaler d’air comprimé.
Utiliser l’air comprimé uniquement pour
Ne pas découper ou gouger à proximité de découper ou gouger ainsi que pour l’outillage
produits inflammables. pneumatique.
Attention aux risques d’incendie: tenir un extincteur à proximité.
OM-244 023 Page 12

Remettre en place les portes, panneaux, recouvrements ou
Une PRESSION D’AIR RÉSIDUELLE dispositifs de protection à la fin des travaux d’entretien et avant
ET DES FLEXIBLES QUI FOUETTENT de mettre le moteur en marche.
risquent de provoquer des blessures.
Détendre la pression pneumatique des outils et

circuits avant d’entretenir, ajouter ou changer DES PIÈCES CHAUDES peuvent
des accessoires et avant d’ouvrir le bouchon provoquer des brûlures graves.
de vidange ou de remplissage d’huile
du compresseur. Ne pas toucher de pièces chaudes
du compresseur ou du circuit d’air.
Prévoir une période de refroidissement
avant d’intervenir sur l’équipement.
Les PIÈCES MOBILES peuvent causer
Ne pas toucher aux pièces chaudes, utiliser les outils
des blessures. recommandés et porter des gants de soudage et
des vêtements épais pour éviter les brûlures.
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs LIRE LES INSTRUCTIONS.
de protection.
Lire et appliquer les instructions sur les
Ne pas approcher les mains, cheveux, vêtements lâches et outils
étiquettes et le Mode d’emploi avant
des organes mobiles. l’installation, l’utilisation ou l’entretien de
Avant d’intervenir sur le circuit d’air comprimé, couper l’appareil. Lire les informations de sécurité au
l’alimentation électrique, verrouiller et étiqueter l’appareil, début du manuel et dans chaque section.
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance. N’utiliser que les pièces de rechange recommandées par le
constructeur.
Demander seulement à un personnel qualifié d’enlever
les dispositifs de sécurité ou les recouvrements pour effectuer, Effectuer l’entretien en respectant les manuels d’utilisation,
s’il y a lieu, des travaux d’entretien et de dépannage. les normes industrielles et les codes nationaux, d’état et locaux.
2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU LES ÉTINCELLES PROJETÉES
D’EXPLOSION. peuvent provoquer des blessures.
Ne pas placer l’appareil sur, au-dessus ou Porter un écran facial pour protéger le visage et
à proximité de surfaces inflammables. les yeux.
Ne pas installer l’appareil à proximité de pro- Affûter l’électrode au tungstène uniquement à
duits inflammables. la meuleuse dotée de protecteurs. Cette ma-
Ne pas surcharger l’installation électrique − s’assurer que l’ali- nœuvre est à exécuter dans un endroit sûr lors-
mentation est correctement dimensionnée et protégée avant de que l’on porte l’équipement homologué de pro-
mettre l’appareil en service. tection du visage, des mains et du corps.
Les étincelles risquent de causer un incendie − éloigner toute
LA CHUTE DE L’ÉQUIPEMENT substance inflammable.
peut provoquer des blessures.
Utiliser l’anneau de levage pour lever l’appareil
et les accessoires correctement installées
Les PIÈCES MOBILES peuvent
seuls, PAS les bouteilles de gaz. Ne pas dé-
passer le poids nominal maximal de l’œilleton
causer des blessures.
(voir les spécifications). Ne pas s’approcher des organes mobiles.
Utiliser un équipement de levage de capacité suffisante pour Ne pas s’approcher des points de coincement
lever l’appareil. tels que des rouleaux de commande.
En utilisant des fourches de levage pour déplacer l’unité, s’assu-
rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil. LES FILS DE SOUDAGE peuvent
Tenir l’équipement (câbles et cordons) à distance des véhicules provoquer des blessures.
mobiles lors de toute opération en hauteur. Ne pas appuyer sur la gâchette avant d’en
Suivre les consignes du Manuel des applications pour l’équation avoir reçu l’instruction.
de levage NIOSH révisée (Publication Nº94−110) lors du levage Ne pas diriger le pistolet vers soi, d’autres per-
manuelle de pièces ou équipements lourds. sonnes ou toute pièce mécanique en enga-
geant le fil de soudage.
LE SURCHAUFFEMENT peut
endommager le moteur électrique. L’EMPLOI EXCESSIF peut
Arrêter ou déconnecter l’équipement avant de SURCHAUFFER L’ÉQUIPEMENT.
démarrer ou d’arrêter le moteur.
Laisser l’équipement refroidir ; respecter le fac-
Ne pas laisser tourner le moteur trop lentement sous risque d’en- teur de marche nominal.
dommager le moteur électrique à cause d’une tension et d’une fré-
quence trop faibles. Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,
s’il y a lieu. Ne pas obstruer les passages d’air du poste.
OM-244 023 Page 13

Demander seulement à des personnes qualifiées familiarisées
LES CHARGES ÉLECTROSTATI- avec des équipements électroniques de faire fonctionner l’installa-
QUES peuvent endommager les tion.
circuits imprimés. L’utilisateur est tenu de faire corriger rapidement par un électricien
Établir la connexion avec la barrette de terre qualifié les interférences résultant de l’installation.
avant de manipuler des cartes ou des pièces. Si le FCC signale des interférences, arrêter immédiatement l’ap-
Utiliser des pochettes et des boîtes antistatiques pour stocker, pareil.
déplacer ou expédier des cartes de circuits imprimes. Effectuer régulièrement le contrôle et l’entretien de l’installation.
UNE REMORQUE QUI BASCULE peut Maintenir soigneusement fermés les portes et les panneaux des
provoquer des blessures. sources de haute fréquence, maintenir les éclateurs à une distan-
ce correcte et utiliser une terre et un blindage pour réduire les
Utiliser les supports de la remorque ou des
interférences éventuelles.
blocs pour soutenir le poids.
Installer convenablement le poste sur la remor-
que comme indiqué dans le manuel s’y rappor- LE SOUDAGE À L’ARC risque de
tant. provoquer des interférences.
LIRE LES INSTRUCTIONS. L’énergie électromagnétique risque de provo-
quer des interférences pour l’équipement élec-
Lire et appliquer les instructions sur les tronique sensible tel que les ordinateurs et
étiquettes et le Mode d’emploi avant l’équipement commandé par ordinateur tel que
l’installation, l’utilisation ou l’entretien de les robots.
l’appareil. Lire les informations de sécurité au Veiller à ce que tout l’équipement de la zone de soudage soit
début du manuel et dans chaque section. compatible électromagnétiquement.
N’utiliser que les pièces de rechange recommandées par le Pour réduire la possibilité d’interférence, maintenir les câbles de
constructeur. soudage aussi courts que possible, les grouper, et les poser
Effectuer l’entretien en respectant les manuels d’utilisation, aussi bas que possible (ex. par terre).
les normes industrielles et les codes nationaux, d’état et locaux. Veiller à souder à une distance de 100 mètres de tout équipe-
ment électronique sensible.
LE RAYONNEMENT HAUTE FRÉ- Veiller à ce que ce poste de soudage soit posé et mis à la terre
QUENCE (H.F.) risque de provoquer conformément à ce mode d’emploi.
des interférences. En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
Le rayonnement haute fréquence (H.F.) peut mentaires telles que le déplacement du poste, l’utilisation de câ-
provoquer des interférences avec les équipe- bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
ments de radio−navigation et de communica- teurs dans la zone de travail.
tion, les services de sécurité et les ordinateurs.
2-7. Proposition californienne 65 Avertissements

cancérogène ainsi que provoquant des malformations
Les équipements de soudage et de coupage produisent des congénitales ou autres problèmes de procréation. Se laver
fumées et des gaz qui contiennent des produits chimiques les mains après toute manipulation.
dont l’État de Californie reconnaît qu’ils provoquent des mal-
formations congénitales et, dans certains cas, des cancers. Pour les moteurs à essence :
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants) Les gaz d’échappement des moteurs contiennent des pro-
duits chimiques dont l’État de Californie reconnaît qu’ils
Les batteries, les bornes et autres accessoires contiennent provoquent des cancers et des malformations congénitales
du plomb et des composés à base de plomb, produits chimi- ou autres problèmes de procréation.
ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres Pour les moteurs diesel :
problèmes de procréation. Se laver les mains après manipu-
lation. Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com-
Ce produit contient des éléments chimiques, dont le plomb, me provoquant des cancers et des malformations
reconnus par l’État de Californie pour leur caractère congénitales ou autres problèmes de procréation.
OM-244 023 Page 14

2-8. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
from Global Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org).
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, from National Fire Protection Association,
and Cutting, American Welding Society Standard AWS F4.1, from Glob- Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
al Engineering Documents (phone: 1-877-413-5184, website: For Standards about hydraulic systems, contact the National Fluid
www.global.ihs.com). Power Association, Publications Department, 3333 North Mayfair
National Electrical Code, NFPA Standard 70, from National Fire Protec- Road, Suite 211, Milwaukee, WI 53222-3219 (phone: (414) 778-3344,
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: website: www.nfpa.com).
www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Indus-
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
from Compressed Gas Association, 4221 Walney Road, 5th Floor, and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
Safety in Welding, Cutting, and Allied Processes, CSA Standard (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
W117.2, from Canadian Standards Association, Standards Sales, 5060 phone for Region 5, Chicago, is 312-353-2220, website:
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: www.osha.gov).
800-463-6727, website: www.csa-international.org). U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
Standards Association, Standards Sales, 5060 Spectrum Way, Suite www.cpsc.gov).
100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: Applications Manual for the Revised NIOSH Lifting Equation, The Na-
www.csa-international.org). tional Institute for Occupational Safety and Health (NIOSH), 1600
Safe Practice For Occupational And Educational Eye And Face Protec- Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
tion, ANSI Standard Z87.1, from American National Standards Institute, www.cdc.gov/NIOSH).
2-9. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs 4. Maintenir la tête et le torse aussi loin que possible du matériel du
électromagnétiques (CEM) à certains endroits. Le courant de soudage circuit de soudage.
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux 5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des 6. Ne pas travailler à proximité d’une source de soudage, ni
restrictions d’accès pour les passants ou une évaluation individuelle s’asseoir ou se pencher dessus.
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant 7. Ne pas souder tout en portant la source de soudage ou le
du circuit de soudage: dévidoir.
1. Rassembler les câbles en les torsadant ou en les attachant avec En ce qui concerne les implants médicaux :
du ruban adhésif ou avec une housse.
Les porteurs d’implants doivent d’abord consulter leur médecin avant
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les de s’approcher des opérations de soudage à l’arc, de soudage par
câbles d’un côté et à distance de l’opérateur. points, de gougeage, du coupage plasma ou de chauffage par induc-
3. Ne pas courber et ne pas entourer les câbles autour de votre tion. Si le médecin approuve, il est recommandé de suivre les
corps. procédures précédentes.
OM-244 023 Page 15

SECTION 3 − DEFINITIONS
3-1. Symbols And Definitions
Fast (Run, Weld/

Stop Engine Slow (Idle) Start Engine
Power)
Check engine belt Check Air Cleaner Starting Aid Engine
Battery (Engine) Hourmeter (HM) Temperature Circuit Protector
Do Not Switch Read Operator’s Certified/Trained

Engine Oil
Under Load Manual Mechanic
Check Injectors/ Check Valve Engine Coolant

Fuel
Pump Clearance Temperature
Positive Negative Wire Feed Welding Arc
A Amperes
V Volts Panel/Local Remote
Direct Current Alternating Gas Tungsten Arc

Output
(DC) Current (AC) Welding (TIG)
Stick (SMAW) Constant Current MIG (GMAW) Constant Voltage

Welding (CC) Welding (CV)
3
Air Carbon Arc Protective Earth
Three Phase
1 Single Phase
Cutting (CAC-A) (Ground)
DC Electrode DC Electrode Electrode

Work Connection
Positive Negative Connection
On Off
h Hours
s Seconds
Time
OM-244 023 Page 16

SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Maximum
Weld Rated Engine
Welding Open-Circuit Generator Power Fuel Tank
Output Welding Engine Oil
Mode Voltage Rating Capacity
Range Output Capacity
(Nominal)
800 A,
32 Volts
CC/DC 20 − 750 A DC, 95
100% Duty Standard DEUTZ 22 qt
Cycle Single-Phase, (20.8 L) 25 gal
4 kVA/kW, 34/17 A, Deutz TD2011L04w Total (95 L)
700 A, 120/240 V AC, Oil-Cooled, Capacity
44 Volts 50/60 Hz Four-Cylinder, (Including
CV/DC 14 − 40 V DC, 56 Turbo-Charged Oil Cooler)
100% Duty 63.4 HP Diesel Engine
Cycle
4-2. Sound Level Table

Weld/Power Speed
Idle Speed (1250 rpm) 40 Volts DC At 500 Amps 44 Volts DC At 600 Amps
(1800 rpm)
93.5 Lwa sound power 100.1 Lwa sound power 102.2 Lwa sound power 104.8 Lwa sound power
66.8 dBa at 23 ft (7 m) 72.0 dBa at 23 ft (7 m) 74.1 dBa at 23 ft (7 m) 76.0 dBa at 23 ft (7 m)
72.2 dBA 3.3 ft (1 m) 78.5 dBA 3.3 ft (1 m) from front 81.9 dBA 3.3 ft (1 m) from front 85.2 dBA 3.3 ft (1 m) from front
from front panel panel panel panel
4-3. Dimensions, Weights, And Operating Angles

Dimensions
54-1/2 in. (1384 mm)
Height
(to top of muffler)
G
28-1/2 in. (724 mm)
(mtg. brackets turned in)
Width
30-3/4 in. (781 mm)
(mtg. brackets turned out)
! Do not exceed tilt angles or engine could
be damaged or unit could tip.
Depth 69-1/2 in. (1765 mm)
! Do not move or operate unit where it
A 69-1/2 in. (1765 mm) could tip.
B* 58 in. (1473 mm)

C* 46-3/8 in. (1178) A
D* 11-5/8 in. (295 mm) B C
E 27-1/2 in. (699 mm)

F 1 in. (25 mm)
G 29-13/16 in. (757 mm) 30°
H
9/16 in. (14 mm) Dia. 30°
H 20°
4 Holes D
Front Panel End 20°
* With mounting brackets in center
position. Dimensions vary with loca-
tion of mounting brackets. F
Weight E
No Fuel: 1835 lb (832 kg)
w/Fuel: 2010 lb (912 kg)
802 161-A
Lifting Eye Weight Rating 803 452
2380 lb (1079 kg) Maximum
Meets IEC Standard 60−974−1
OM-244 023 Page 17

4-4. Stick And MIG Volt-Ampere Curves
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
A. DC Stick Mode other settings fall between the
curves shown.
100
Ranges
300−Max
185−525
125−400
80 85−250
60
DCVOLTS
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
DCAMPERES
B. MIG Mode
100
80
60
DCVOLTS
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
DCAMPERES
240 048-A / 240 049-A
OM-244 023 Page 18

4-5. DC TIG Volt-Ampere Curves
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
100
80
60
DCVOLTS
40
20
0
0 100 200 300 400 500 600 700
DCAMPERES
251 479-A
4-6. Fuel Consumption

The curve shows typical fuel use
under weld or generator power
loads.
3.00
2.75
2.50
2.25
2.00
US Gal./Hr.
1.75
1.50
1.25
1.00
0.75
0.50
Idle
0.25
0.00
0 50 100 150 200 250 300 350 400 450 500 550 600
DC WELD AMPERES AT 100% DUTY CYCLE
Ref. 240 053-A
OM-244 023 Page 19

4-7. Generator AC Power Curve
The ac power curve shows the gen-
erator power in amperes available
at the 120 and 240 volt receptacles.
150 300
125 250
100 200
AC VOLTS
75 150
50 100
25 50
0 0
0 5 10 15 20 25 30
AC AMPERES IN 240V MODE
0 10 20 30 40 50 60
AC AMPERES IN 120V MODE
240 054-A
OM-244 023 Page 20

SECTION 5 − INSTALLATION
5-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the front. Use rating label to determine input power
requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
5-2. Installing Welding Generator
! Do not move or operate unit
where it could tip.
! Always securely fasten weld-
Movement ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
ble codes.
NOTICE − Do not install unit where
air flow is restricted or engine may
overheat.
OR OR
See Section 4-3 for lifting eye
rating.
See Section 5-3 for mounting in-

formation.
Location/Airflow Clearance
OR OR
18 in.
(460 mm)
18 in.
18 in. (460 mm)
(460 mm)
18 in.
18 in. (460 mm)
(460 mm)
install3 2008-01 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712
OM-244 023 Page 21

5-3. Mounting Welding Generator
! Do not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
Supporting The Unit brackets or bolt unit down.
NOTICE − Do not mount unit by
supporting the base only at the four
mounting brackets. Use cross-sup-
ports to adequately support unit
2 and prevent damage to base.
Mounting Surface:
1 Cross-Supports
2 Mounting Brackets (Supplied)
OR
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brack-
ets.
1 3 1/2 in. Bolt And Washer
(Minimum − Not Supplied)
4 3/8-16 x 1 in. Screws
(Supplied)
To Bolt Unit In Place:
Remove hardware securing the
1 four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
Mount unit to truck or trailer with 1/2
Using Mounting Brackets in. (12 mm) or larger hardware (not
supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
2
Welding Unit In Place

Bolting Unit In Place
2 3
Tools Needed:
9/16 in.
install3 2008-01 803 274 / 200 864-A / 803 602
OM-244 023 Page 22

5-4. Grounding Generator To Truck Or Trailer Frame
! Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
! Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
! Bed liners, shipping skids,
and some running gear insu-
late the welding generator
from the vehicle frame. Al-
ways connect a ground wire
from the generator equip-
ment grounding terminal to
bare metal on the vehicle
frame as shown.
1 2
! If unit does not have GFCI re-
GND/PE ceptacles, use GFCI-pro-
tected extension cord.
1 Equipment Grounding
Terminal (On Front Panel)
2 Grounding Cable (Not
Supplied)
3 Metal Vehicle Frame
3
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
Electrically bond generator

frame to vehicle frame by met-
al-to-metal contact.
rot_grnd 2008-01 − 800 652-D
OM-244 023 Page 23

5-5. Installing Exhaust Pipe
! Stop engine and let cool.
Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in. Exhaust1 2008−01 Ref. 803 604 / Ref. 215 664
5-6. Installing Optional Spark Arrestor Muffler

1 Spark Arrestor Muffler
2
2 Double-Flanged Elbow
3 Nut
10 1 4 Flat Washer
9 5 Mount
6 Bracket
7 Screw
8 Single-Flanged Elbow
9 Rain Cap
10 Clamp
7
Loosely assemble components as
shown.
Mount the muffler with the clean-

6 out plug to the outside.
8
After assembly, final-tighten all
5 clamps and hardware.
4
Be sure to tighten rain cap
3 mounting screw.
Tools Needed:
7/16, 1/2 in.
803 453
OM-244 023 Page 24

5-7. Activating The Dry Charge Battery (If Applicable)
! Always wear a face shield,
rubber gloves and protective
clothing when working on a
battery.
3
Remove battery from unit.
1 Vent Caps
2 2 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
1 3 Well
Fill each cell with electrolyte to
bottom of well (maximum).
! Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
4 Battery Charger
! Read and follow all instruc-
tions supplied with battery
charger.
5 5 Amperes For 30 Minutes
Charge Time
5 6 30 Amperes For 12 Minutes
4 Charge Time
Charge battery. Disconnect charg-
ing cables and install battery.
When electrolyte is low, add

only distilled water to cells to
5A maintain proper level.
+
6
−
Tools Needed: 30 A
drybatt 12008−01 − S-0886
5-8. Connecting The Battery

! Connect negative (−) battery
cable last
Reinstall cover after connecting

battery.
Tools Needed:
1/2 in.
802 168-E / Ref. 202 705 / 802 313 / S-0756-C
OM-244 023 Page 25

5-9. Using The Optional Battery Disconnect Switch
! Stop engine.
1 Battery Disconnect Switch
1 OFF The battery disconnect switch dis-
connects battery voltage from the
circuit. When the switch is turned
Off, the front panel controls do not
work.
To run unit, turn switch to On posi-
ON tion. To prevent unit from running,
turn switch to Off position.
The switch may be locked using a
customer-supplied padlock.
803 454 / Ref. 803 324
OM-244 023 Page 26

5-10. Engine Prestart Checks
Engine Oil
Engine stops if fuel level is low.
Full
Diesel
Engine
Oil Level
Cold High
Warm High
Cold Low
Warm
Low
803 454 / 244 400-A
Check all engine fluids daily. Fuel Cold Weather Starting

NOTICE − Do not use gasoline. Gasoline
will damage engine. To improve cold weather starting:
Engine must be cold and on a level surface. Use Starting Aid switch (see Section
Add fresh diesel fuel before starting to pre- 6-1).
The automatic shutdown system stops en-
vent air from entering the fuel system (see
gine if oil pressure is too low or coolant tem-
engine maintenance label for fuel specifica- Keep battery in good condition. Store
perature is too high.
tions). Leave filler neck empty to allow room
battery in warm area.
for expansion.
This unit has a low oil pressure shut- Engine stops if fuel level is low. Use fuel formulated for cold weather
down switch. However, some condi- (diesel fuel can gel in cold weather).
Engine Oil
tions may cause engine damage before Contact local fuel supplier for fuel in-
the engine shuts down. Check oil level After fueling, check oil with unit on level sur- formation.
often and do not use the oil pressure face. Oil level on a cold engine should be
shutdown system to monitor oil level. between cold low and cold high indicators Use correct grade oil for cold weather
on dipstick. Oil level on a warm engine (see Section 8-2).
should be between warm high and warm
Follow run-in procedure in engine manual. low indicators on dipstick. Add oil if neces-
If unburned fuel and oil collect in exhaust sary (see maintenance label for engine oil
pipe during run-in, see Section 11. specifications).
OM-244 023 Page 27

5-11. Connecting To Weld Output Terminals
Stick And TIG Welding MIG And FCAW Welding

For Stick welding Direct Current Electrode For MIG welding Direct Current Electrode
Positive (DCEP), connect electrode hold- Positive (DCEP), connect wire feeder
er cable to Positive (+) terminal on left and cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on work cable to Negative (−) terminal on
right. right. Use Process/Contactor switch to
select type of weld output (see Section
For Stick and TIG Direct Current Elec-
6-3).
trode Negative (DCEN), connect elec-
trode holder cable to Negative (−) terminal For MIG and FCAW Direct Current Elec-
on right and work cable to Positive (+) ter- trode Negative (DCEN), connect wire
minal on left. feeder cable to Negative (−) terminal on
right and work cable to Positive (+) termi-
nal on left. Use Process/Contactor switch
to select type of weld output (see Section
! Stop engine.
6-3).
! Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
Do not place anything between weld cable

terminal and copper bar. Make sure that
the surface of the weld cable terminal and
copper bar are both clean.
1 Correct Weld Cable Connection
2 Incorrect Weld Cable Connection
3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output termi-
nal. Slide weld cable terminal onto weld output
terminal and secure with nut so that weld cable
terminal is tight against copper bar.
7 Positive (+) Weld Output Terminal
8 Negative (−) Weld Output Terminal
Tools Needed: 7
3/4 in.
1 2
6
3
Ref 803 452 / 803 778-B
OM-244 023 Page 28

5-12. Selecting Weld Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
! Turn off power before
connecting to weld
output terminals. 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
! Do not use worn, dam- (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
aged, undersized, or
poorly spliced cables.
10 − 60% 60 − 100%
Welding
Duty Duty 10 − 100% Duty Cycle
Amperes
Cycle Cycle
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
2 ea. 2/0 2 ea. 2/0

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0
600 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0
700 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120) (4x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0 4 ea. 4/0
800 4/0 (120)
(2x70) (2x95) (2x120) (3x120) (3x120) (4x120) (4x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart)
Ref. S-0007-G 2009−08
OM-244 023 Page 29

5-13. Connecting To Remote 14 Receptacle RC14
Socket* Socket Information
A 24 volts ac. Protected by sup-

plementary protector CB5 (see
Section 8-9).
24 VOLTS AC
B Contact closure to A completes

24 volt ac contactor control
circuit.
C Output to remote control:+10

volts dc in MIG or Stick mode;
0 to +10 volts dc in TIG mode.
REMOTE D Remote control circuit common.

OUTPUT
CONTROL E DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
115 volts, 10 amperes, 60 Hz

ac. Protected by supplementary
I
OR protector CB6 (see Section
115 VOLTS AC 8-9).
Contact closure to I completes

J 115 volt ac contactor control
circuit.
GND K Chassis common.

803 452
NEUTRAL G Circuit common for 24 and 115

volt ac circuit.
*The remaining sockets are not used.
OM-244 023 Page 30

5-14. Connections To Terminal Strip T10
1 Terminal Strip T10
There are two bushings on the aux-
iliary power panel through which
leads can be routed to T10.
1
YELLOW
NEG YELLOW /GREEN BROWN PURPLE BLUE ORANGE PINK RED BLACK POS
NEG J K E B A POS
EQUIPMENT 24VAC
GROUND 115VAC
NEUTRAL 1K
093727-00-11219
OM-244 023 Page 31

SECTION 6 − OPERATING THE WELDING GENERATOR
6-1. Controls (See Section 6-2)
8 9 11 12 6 5 3
7 2
10
1
803 454 /239 132-A
OM-244 023 Page 32

6-2. Description Of Controls (See Section 6-1)
Engine Starting Controls if fuel level is low. For most welding applications, use lowest
1 Starting Aid Switch amperage range possible to help prevent arc
To check fuel level when engine is not run-
outages.
Use switch to energize starting aid for cold ning, turn Engine Control switch to Run posi-
weather starting. tion. 9 Voltage/Amperage Adjust Control
Push switch up for 60 seconds to operate the See Section 6-5 for complete fuel/hour gauge With Process/Contactor switch in any Stick or
starting aid (intake air heater) before cranking information. TIG setting, use control to adjust amperage
engine (see starting instructions following). 4 Engine Oil Pressure Gauge within range selected by Ampere Range
switch. With Process/Contactor switch in any
2 Engine Control Switch Normal pressure is 30 − 60 psi (206 − 414 MIG position, use control to adjust voltage.
Use switch to start engine, select engine kPa). Engine stops if pressure is below 20 psi With Panel/Remote Switch in Remote posi-
speed, and stop engine. (138 kPa). tion, control limits the remote amperage in
5 Engine Temperature Gauge TIG mode, but has no effect in Stick and MIG
In Run position, engine runs at weld/power
modes.
speed. Normal temperature is 212 - 239° F (100 -
To Start: 115° C). Engine stops if temperature exceeds Weld output would be about 263 A DC with
270° F (132° C). controls set as shown (50% of 125 to 400 A).
If engine does not start, let engine come 6 Battery Voltmeter
to a complete stop before attempting re- The numbers around the Voltage/Amper-
start. Use gauge to check battery voltage and moni- age Adjust control are for reference only
tor the engine charging system. The meter and do not represent an actual percent-
Above 32 F (0 C): turn Engine Control should read about 14 volts dc when the en- age value.
switch to Start. Release Engine Control gine is running, and about 12 volts dc when
switch when engine starts. the engine is stopped. 10 Panel/Remote Switch And Remote 14
Receptacle
Below 32 F (0 C) using starting aid Weld Controls
switch: Use switch to select front panel or remote
Push Starting Aid switch up for 60 seconds. 7 Process/Contactor Switch
voltage/amperage control. For remote con-
While still holding Starting Aid switch, turn En- See Section 6-3 for Process/Contactor trol, place switch in Remote position and con-
gine Control switch to Start. Release Engine switch information. nect remote control to Remote 14 receptacle
Control switch and Starting Aid switch when RC14 (see Sections 5-13 and 6-4).
8 Ampere Range Switch
engine starts.
NOTICE − Do not switch under load. Weld Meters
To Stop: turn Engine Control switch to Off
position. Use switch to select weld amperage range. 11 AC/DC Voltmeter
Engine Gauges Use all five ranges for Stick welding, and the Voltmeter displays voltage at the weld output
lowest four ranges for TIG welding. Read the terminals, but not necessarily the welding arc
3 Engine Hour Meter/Fuel Gauge
upper set of numbers at each range for Stick due to resistance of cable and connections.
Use gauge to monitor engine running time for welding and the lower set at each range for
scheduling maintenance and to determine TIG welding. 12 AC/DC Ammeter
cause of engine shutdowns.
Use the highest range for MIG welding and for Ammeter displays amperage output of the
Use gauge to check fuel level. Engine stops cutting and gouging (CAC-A). unit.
OM-244 023 Page 33

6-3. Process/Contactor Switch
1 Process/Contactor Switch
! Weld output terminals are ener-
gized when Process/Contactor
switch is in a Weld Terminals Al-
ways On position and the en-
gine is running.
! DC voltage is still present at the
weld terminals when Process/
1 Contactor switch is in the Re-
mote On/Off Switch Required −
Stick position and the engine is
running.
Use switch to select weld process and
weld output on/off control (see table be-
low and 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.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use Stick position for air carbon arc
(CAC-A) cutting and gouging.
When switch is in a Stick position, the
arc drive (dig) circuit provides addition-
al amperage during low voltage (short
arc length conditions) to prevent “stick-
ing” electrodes.
The arc drive (dig) circuit is disabled
when switch is in MIG or TIG positions.
The engine auto idle option does

not work in the Remote On/Off
Switch Required-TIG mode.
236 975-A
Process/Contactor Switch Settings
Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)
Remote On/Off Switch Re-

GTAW With HF Unit, Pulsing
quired − TIG, HF Required At Remote 14 Receptacle Not Active
Device, Or Remote Control
Or Scratch Start TIG
Remote On/Off Switch

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

Required − CV Feeder MIG (GMAW) At Remote 14 Receptacle Active
Using Remote
Weld Terminals Always On −

MIG (GMAW) Electrode Hot Active
Wire
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting Electrode Hot Active
Stick
And Gouging

TIG Scratch Start (GTAW) Electrode Hot Active
TIG, Scratch Start
OM-244 023 Page 34

6-4. Using Remote Voltage/Amperage Control
1 Remote 14 Receptacle RC14
Connect optional remote control to
RC14 (see Section 5-13).
803 454
Example: Combination Remote Amperage Control (Stick) In Example:

Process = Stick (Using Remote On/Off)
Range = 125 to 400 A DC
Min = 125 A DC
Max = 400 A DC
Max (400 A DC)
Min (125 A DC)

Set Set Remote
Set Range Control Not Adjust Optional Remote Control
Panel/Remote Process
Used In Remote
Switch Stick Mode
Example: Combination Remote Amperage Control (TIG) In Example:

Process = TIG (Using Remote On/Off)
Range = 40 to 330 A DC
Percentage Of Range = 50%
Min = 40 A DC
Max = About 185 A DC (50% of 40 to 330)
Max (185 A DC)
Min (40 A DC)

Set Set Remote
Set Range Set Control Adjust Optional Remote Control
Panel/Remote Process
Switch
0774 / Ref. 236 975-A / 802 311-A
OM-244 023 Page 35

6-5. Fuel/Hour Gauge Descriptions
OM-244 023 Page 36

SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. Auxiliary Power Receptacles
4
3 5
238 127-A / 805 259-A
1 Circuit Breaker CB1 power at weld/power speed. Maximum combined output of all recep-
CB1 protects GFCI1 from overload. If a cir- tacles is 4 kVA/kW.
If a ground fault is detected, receptacle Re-
cuit breaker opens, the receptacle does not EXAMPLE: If 13 A is drawn from RC1, only
set button pops out and receptacle does not
work. Press CB1 to reset breaker. 7 A is available at GFCI1:
work. Check for faulty tools plugged into re-
2 Circuit Breaker CB2 ceptacle. Press button to reset receptacle. (240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
CB2 protects GFCI1 from overload. If a cir-
cuit breaker opens, the receptacle does not At least once a month, run engine at If a circuit breaker continues to open,
work. Press CB2 to reset breaker. weld/power speed and press test but- contact Factory Authorized Service
ton to verify GFCI is working properly. Agent.
3 120V 15/20A AC Receptacles GFCI1,
GFCI2 Maximum output is 2.4 kVA/kW from each 4 Strain Relief Bushings
Receptacles supply 60 Hz single-phase GFCI and 4 kVa/kW from RC1. 5 Ground Stud
OM-244 023 Page 37

SECTION 8 − ENGINE/GENERATOR MAINTENANCE
8-1. Routine Maintenance
! Stop engine before maintaining.
Recycle engine
See Engine Manual and Maintenance Label
for important start-up, service, and storage
fluids.
information. Service engine more often if
used in severe conditions.
= Check = Change = Clean = Replace Reference

* To be done by Factory Authorized Service Agent
Every Section
8 FUEL 5-10, 8-8
WATER Cold High
Hours
Warm High
Cold Low
Warm Low
Fuel/Water Separator Fuel Level Oil Level Oil, Fuel Spills
Every
50
Hours
Weld Terminals
Every Section 8-4
100
Hours
Battery Terminals Air Cleaner Hoses Air Cleaner Element

Every Engine
250 1/2 in. Manual,
(13 mm)
Hours Section 8-5
Unreadable Labels Fan Belt Tension Cooling System Spark Arrestor

Every NOTICE − Change engine
500 oil and filter after initial 50 to
Hours 75 hours of use.
Weld Cables Oil Oil Filter

Every Section 8-8,
FUEL
1000 OR 8-6 and
Hours Engine
Manual
SLUDGE
Fuel Filter Inside Unit Valve Clearance* Drain Sludge
Slip Rings*
Brushes*
Every
3000
Hours
Injectors*
Every
6000
Hours
or 5
Years
Engine Timing Belt
OM-244 023 Page 38

8-2. Engine Maintenance Label
OM-244 023 Page 39

8-3. Operating Optional Oil Pan Heater
1 Optional Oil Heater Plug

Use heater to maintain a constant
engine oil temperature.
To turn on heater, connect heater
plug to receptacle.
! Do not run engine while oil
pan heater is on.
NOTICE −In extremely cold weath-
er, heater should be connected to
power source when engine oil is
warm to eliminate possibility of oil
coking on heater.
Severe coking on heater element
may cause damage to engine, en-
gine oil, and oil pan heater.
! The area near the the oil pan
heater gets hot.
Disconnect plug to turn off heater.
803 452 / Ref. 803 145
OM-244 023 Page 40

8-4. Servicing Air Cleaner
! Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged ele-
ment is not covered by the warranty.
1 Engine Air Cleaner
The air cleaner primary element can
be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.
If you decide to clean the primary ele-

ment, we strongly recommend instal-
1 ling an optional safety element to pro-
vide additional engine protection.
Never clean a safety element. Re-
place the safety element after servic-
ing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
2 3 4 5
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
2 Housing
3 Safety Element (Optional)
4 Primary Element
5 Dust Cap
Optional 6 Dust Ejector
6 To clean air filter:
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
NOTICE − Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in. (3 mm) nozzle and
keep nozzle at least 2 in. (51 mm) from
Keep nozzle inside of element. Replace primary ele-
2 in. (51 mm) ment if it has holes or damaged gaskets.
from element. Reinstall primary element and cap (dust
ejector down).
Blow Inspect
aircleaner1 9/00 − 803 454 / 153 929-B / 153 585 / Ref. S-0698-B
OM-244 023 Page 41

8-5. Inspecting/Cleaning Optional Spark Arrestor Muffler

1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
Start engine and run at idle speed to
blow out cleanout hole. If nothing
2 blows out of hole, briefly cover end
1 of exhaust pipe with fireproof
material.
Reinstall cleanout plug.
Tools Needed:
3/8 in.
803 452 / 803 230
8-6. Checking Generator Brushes

1 Generator Brush
Remove brushes from brush holder.
Replace brushes if damaged or if brush
material is at or near minimum length.
Minimum Length:
5/8 in. (16 mm)
New Length: 1-1/4 in. (32 mm)
Replace
Damaged Brushes 1
Ref. 206 467
8-7. Engine Speed Adjustment

The engine is electronically governed and does not require engine speed adjustment. If adjustment is necessary, contact engine manufacturer’s
Factory Authorized Service Agent.
OM-244 023 Page 42

8-8. Servicing Engine Fuel And Lubrication Systems
Tools Needed:
7
6
2
803 454
! Stop engine and let cool. To drain water from fuel system: To drain sludge from fuel tank:
! After servicing, start engine and Open primary fuel filter petcock and drain
check for fuel leaks. Stop engine, water into metal container. Close petcock ! Beware of fire. Do not smoke and
tighten connections as necessary, when water-free fuel flows. keep sparks and flames away from
and wipe up spilled fuel. drained fuel. Dispose of drained fuel
To replace primary fuel filter:
1 Oil Filter in an environmentally-safe manner.
2 Oil Drain Hose And Valve Turn filter counterclockwise. Remove filter. Do not leave unit unattended while
draining fuel tank.
3 Oil Fill Cap Apply thin coat of fuel to gasket on new filter.
4 Primary Fuel Filter (Fuel/Water Fill filter with fuel. Install filter and turn clock-
Separator) wise until tight. Bleed air from fuel system ! Properly lift unit and secure in a level
5 Petcock according to engine manual. position. Use adequate blocks or
stands to support unit while drain-
6 Secondary Fuel Filter Inspect fuel lines, and replace if cracked or ing fuel tank.
worn.
7 Fuel Tank Sludge Drain Valve
To change oil and filter: To replace secondary fuel filter: Attach 1/2 ID hose to drain valve. Put metal
Route engine oil drain hose through hole in See engine manual. container under drain, and use screwdriver
base. See engine manual and engine main- to open sludge drain valve. Close valve
tenance label for oil specifications. Close doors. when sludge has drained. Remove hose.
OM-244 023 Page 43

8-9. Engine/Generator Overload Protection
! Stop engine.
When a supplementary protector,

circuit breaker or fuse opens, it
usually indicates a more serious
problem exists. Contact Factory
Authorized Service Agent.
1 Fuse F1
2 Fuse F2
F1 and F2 protect the stator exciter
winding from overload. If F1 opens,
weld and generator power is low or
stops entirely. If F2 opens, weld output
is low or stops entirely. 4 kVA/kW gen-
erator power is still available.
3 Circuit Breaker CB4 (Not Shown)
4 Supplementary Protector CB5
2 1
6 Circuit Breaker CB10 (Not
Shown)
9
8 10 Circuit Breaker CB16
(Not Shown)
7
CB4 protects the welding arc drive (dig)
circuit. If CB4 opens, electrode may
stick to the workpiece more frequently
during low voltage (short arc length)
conditions. CB4 automatically resets
when the fault is corrected.
CB5 protects the 24 volt ac output to re-
mote receptacle RC14, and 24 volt out-
put to field current regulator board PC1.
If CB5 opens, weld output and 24 volt
output to RC14 stops. On units with op-
4 tional power plant, power at receptacle
5 RC5 also stops if CB5 opens.
CB6 protects the 115 volt ac output to
remote receptacle RC14. If CB6 opens,
115 volt output to RC14 stops.
CB10 protects the engine battery cir-
cuit. If CB10 opens, the engine will not
crank. CB10 automatically resets when
the fault is corrected.
CB11 protects the engine wiring har-
ness. If CB11 opens, weld output stops
(generator power is still available).
CB12 protects the field flashing circuit.
If CB12 opens, the generator may not
excite at start-up and weld and genera-
tor power output may not be available.
CB13 protects the engine shutdown cir-
cuit. If CB13 opens, the engine cranks
but does not start.
Press button to reset.
CB16 protects the glow plug circuit. If
CB16 opens, the glow plug will not oper-
ate. CB16 automatically resets when
the fault is corrected.
Ref. 803 229
OM-244 023 Page 44

SECTION 9 − TROUBLESHOOTING
9-1. Troubleshooting Tables
A. Welding
Trouble Remedy
No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at ac receptacles. position and connect remote contactor to Remote 14 receptacle RC14 (see Sections 5-13 and 6-1).
Check position of Ampere Range switch.
Reset supplementary protector CB11 (see Section 8-9).
Reset supplementary protector CB5 (see Section 8-9). Check for faulty remote device connected to
RC14.
Check and secure connections to Remote 14 receptacle RC14 (see Section 5-13).
Have Factory Authorized Service Agent check connector board PC6 and connections.
Check fuse F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check
brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor.
No weld output or generator power Disconnect equipment from generator power receptacles during start-up.
output.
Check fuses F1 and F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Reset supplementary protector CB12 (see Section 8-9).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output. Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Have Factory Authorized Service Agent check brushes and slip rings.
High weld output. Check position of Ampere Range switch and Voltage/Amperage Adjust control.
Engine speed may need adjustment. Contact engine manufacturer’s Factory Authorized Service
Agent.
Have Factory Authorized Service Agent check field current regulator board PC1.
Voltage/Amperage control does not Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere
work when welding in Stick mode. Range switch in highest range.
Low weld output. Check position of Ampere Range switch and Voltage/Amperage Adjust control.
Engine speed may need adjustment. Contact engine manufacturer’s Factory Authorized Service
Agent.
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 8-9).
frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.
length) conditions.
Low open-circuit voltage. Engine speed may need adjustment. Contact engine manufacturer’s Factory Authorized Service Agent.
Check position of Process/Contactor switch.
OM-244 023 Page 45

Trouble Remedy
No remote fine amperage or voltage Place Panel/Remote switch in Remote position.

control.
Repair or replace remote control device.
Have Factory Authorized Service Agent check PC1 current sensing leads (36 and 37), and connections.
Constant speed wire feeder does not Reset supplementary protector(s) CB5 and CB13 (see Section 8-9).
work.
Repair or replace wire feeder.
Low CV weld output. Set Ampere Range switch to highest range.
Increase Voltage/Amperage Adjust Control setting.
Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Panel/Remote switch.
Repair or replace remote control device.
Have Factory Authorized Service Agent check field current regulator board PC1.
B. Generator Power
Trouble Remedy
No generator power output at ac recep- Reset receptacle supplementary protectors.

tacles; weld output okay.
Reset GFCI receptacle.
No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
check integrated rectifier SR1, capacitor C9, diode/capacitor board D1/C1, and the rotor.
Reset supplementary protectors CB12. Have Factory Authorized Service Agent check field current regu-
lator board PC1 (see Section 8-9).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power Engine speed may need adjustment. Contact engine manufacturer’s Factory Authorized Service Agent.
receptacles.
Have Factory Authorized Service Agent adjust field current resistor R3.
Low output at generator power Engine speed may need adjustment. Contact engine manufacturer’s Factory Authorized Service Agent.
receptacles.
Check fuse F1, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check inte-
grated rectifier SR1, resistor R3, and capacitor C9.
C. Engine
Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8-9).
Have Factory Authorized Service Agent check engine wiring harness and components.
Check engine wiring harness plug connections.
Turn optional battery disconnect switch to On position (see Section 5-9).
Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, and diode/
capacitor board D8/C8.
OM-244 023 Page 46

Trouble Remedy
Engine cranks but does not start. Check fuel level. Optional low fuel shutdown stops engine if fuel level is low.
Reset supplementary protector CB13 (see Section 8-9). Have Factory Authorized Service Agent check
engine wiring harness and components.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check fuel/hour gauge, control relay CR5, fuel pump, and fuel
solenoid FS1.
Air in fuel system. See engine manual.
Engine starts, but stops when Engine Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
Control switch is released. is too high (see Section 5-10).
Have Factory Authorized Service Agent check fuel/hour gauge, and control relay CR5.
Engine hard to start in cold weather. Use starting aid switch (see Section 6-1). If Starting Aid switch does not work have Factory Authorized
Service Agent check Engine Control switch S2, control relay CR8, and circuit breaker CB16.
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 8-2 ).
Engine suddenly stops. Check fuel level. Optional low fuel shutdown stops engine if fuel level is low.
Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Section 5-10).
Have Factory Authorized Service Agent check fuel/hour gauge, control relay CR5, fuel pump, and fuel
solenoid FS1.
See engine manual.
Engine slowly stopped and cannot be Check fuel level.

restarted.
Check engine air and fuel filters (see Sections 8-4 and 8-8).
See engine manual.
Battery discharges between uses. Turn Engine Control switch S1 off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine idles, but does not come up to Have Factory Authorized Service Agent check idle module PC7.
weld speed.
Engine does not run at idle speed. Turn Process/Contactor switch to any position but Remote-TIG.
Allow circuit breaker CB14 to reset.
Have Factory Authorized Service Agent check idle module PC7, control relays CR3 and CR6, and current
transformer CT1.
Engine uses oil during run-in period; Dry engine (see Section 11).
wetstacking occurs.
OM-244 023 Page 47

SECTION 10 − ELECTRICAL DIAGRAM
Figure 10-1. Circuit Diagram For Welding Generator

OM-244 023 Page 48
244 022-B
OM-244 023 Page 49

SECTION 11 − RUN-IN PROCEDURE
run_in1 2007−04
11-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts
weld output and do not exceed duty
cycle or equipment damage may
occur.
1 Welding Generator
2 Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
NOTICE − Do not idle engine longer
than necessary. Piston rings seat
faster if engine runs at weld/power
rpm, and the welding generator is
kept loaded during run-in.
1
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for addition-
al engine run-in information.
OM-244 023 Page 50

11-2. Run-In Procedure Using Load Bank
! Stop engine.
! Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
4 ! Keep exhaust and pipe away
from flammables.
2 NOTICE − Do not perform run-in
procedure at less than 20 volts weld
1 output and do not exceed duty
occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe correct
polarity.
Start engine and run for several
3 minutes.
Set load bank switches and then
adjust generator A/V control so
load equals rated voltage and
current of generator (see name-
plate, rating label, or the specifi-
cations section in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.
Repeat procedure if wetstacking is
present.
S-0683
OM-244 023 Page 51

11-3. Run-In Procedure Using Resistance Grid
! Stop engine.
! Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
6
! Keep exhaust and pipe away
from flammables.
2
NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty
occur.
1 Resistance Grid
Use grid sized for generator rated
1 output.
Turn Off grid.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connec-
tors (polarity is not important).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
3 5 shown, if not provided on generator.
Start engine and run for several
minutes.
Set grid switches and then ad-
just generator A/V control so
load equals rated voltage and
4 current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).
+ Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.
Repeat procedure if wetstacking is
present.
S-0684
OM-244 023 Page 52

SECTION 12 − GENERATOR POWER GUIDELINES
The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
12-1. Selecting Equipment
1 Generator Power Receptacles

− Neutral Bonded To Frame
2 3-Prong Plug From Case
Grounded Equipment
3 2-Prong Plug From Double
1 Insulated Equipment
Be sure equipment has double
insulated symbol and/or word-
2 ing on it.
! Do not use 2-prong plug un-
less equipment is double in-
sulated.
OR
gen_pwr 2010−04 − ST-800 577
12-2. Grounding Generator To Truck Or Trailer Frame
! Always ground generator

frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
Generators.
Terminal (On Front Panel)
2 Grounding Cable (Not
Supplied)
3 Metal Vehicle Frame
Connect cable from equipment
1 2 ground terminal to metal vehicle
frame. Use #8 AWG or larger insu-
GND/PE
lated copper wire.
Electrically bond generator

frame to vehicle frame by met-
al-to-metal contact.
! Bed liners, shipping skids,
3 and some running gear insu-
late the welding generator
from the vehicle frame. Al-
ways connect a ground wire
from the generator equip-
ment grounding terminal to
bare metal on the vehicle
frame as shown.
! If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.
800 652-D
OM-244 023 Page 53

12-3. Grounding When Supplying Building Systems
1 2 Terminal
GND/PE 2 Grounding Cable
Use #8 AWG or larger insulated
copper wire.
3 Ground Device
Use ground device as stated in
electrical codes.
! Ground generator to system
earth ground if supplying
2 3 power to a premises (home,
shop, farm) wiring system.
Generators.
ST-800 576-B
12-4. How Much Power Does Equipment Require?
1 Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2 Non-Resistive Load
Equipment with a motor is a non-re-
3 sistive load and requires approxi-
VOLTS 115 mately six times more power while
2 AMPS 4.5 starting the motor than when running
1 Hz 60 (see Section 12-8).
3 Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
3 Example 1: If a drill uses 4.5 am-
peres at 115 volts, calculate its run-
ning power requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Ex-
ample 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-244 023 Page 54

12-5. Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Split Phase 1/8 HP 800 300
1/6 HP 1225 500
1/4 HP 1600 600
1/3 HP 2100 700
1/2 HP 3175 875
Capacitor Start-Induction Run 1/3 HP 2020 720
1/2 HP 3075 975
3/4 HP 4500 1400
1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000
5 HP 23300 6000
7-1/2 HP 35000 8000
10 HP 46700 10700
Fan Duty 1/8 HP 1000 400
1/6 HP 1400 550
1/4 HP 1850 650
1/3 HP 2400 800
1/2 HP 3500 1100
12-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts
Stock Tank De-Icer 1000 1000
Grain Cleaner 1/4 HP 1650 650
Portable Conveyor 1/2 HP 3400 1000
Grain Elevator 3/4 HP 4400 1400
Milk Cooler 2900 1100
Milker (Vacuum Pump) 2 HP 10500 2800
FARM DUTY MOTORS 1/3 HP 1720 720
Std. (e.g. Conveyors, 1/2 HP 2575 975
Feed Augers, Air 3/4 HP 4500 1400
Compressors) 1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
High Torque (e.g. Barn 1-1/2 HP 8100 2000
Cleaners, Silo Unloaders, 5 HP 23300 6000
Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000
10 HP 46700 10700
3-1/2 cu. ft. Mixer 1/2 HP 3300 1000
High Pressure 1.8 Gal/Min 500 PSI 3150 950
Washer 2 gal/min 550 PSI 4500 1400
2 gal/min 700 PSI 6100 1600
Refrigerator or Freezer 3100 800
Shallow Well Pump 1/3 HP 2150 750
1/2 HP 3100 1000
Sump Pump 1/3 HP 2100 800
1/2 HP 3200 1050
OM-244 023 Page 55

12-7. Approximate Power Requirements For Contractor Equipment
Contractor Rating Starting Watts Running Watts
Hand Drill 1/4 in 350 350
3/8 in 400 400
1/2 in 600 600
Circular Saw 6-1/2 in 500 500
7-1/4 in 900 900
8-1/4 in 1400 1400
Table Saw 9 in 4500 1500
10 in 6300 1800
Band Saw 14 in 2500 1100
Bench Grinder 6 in 1720 720
8 in 3900 1400
10 in 5200 1600
Air Compressor 1/2 HP 3000 1000
1 HP 6000 1500
1-1/2 HP 8200 2200
2 HP 10500 2800
Electric Chain Saw 1-1/2 HP, 12 in 1100 1100
2 HP, 14 in 1100 1100
Electric Trimmer Standard 9 in 350 350
Heavy Duty 12 in 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in 400 400
Flood Lights HID 125 100
Metal Halide 313 250
Mercury 1000
Sodium 1400
Vapor 1250 1000
Submersible Pump 400 gph 600 200
Centrifugal Pump 900 gph 900 500
Floor Polisher 3/4 HP, 16 in 4500 1400
1 HP, 20 in 6100 1600
High Pressure Washer 1/2 HP 3150 950
3/4 HP 4500 1400
1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900
2-1/2 HP 1300 1300
OM-244 023 Page 56

12-8. Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements

Motor Start G H J K L M N P
Code
KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0
1 Motor Start Code

2 Running Amperage
3 Motor HP
4 4 Motor Voltage
AC MOTOR 2
1 To find starting amperage:
VOLTS 230 AMPS 2.5
3 CODE M Hz 60 Step 1: Find code and use table to
find kVA/HP. If code is not listed,
HP 1/4 PHASE 1 multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amper-
age (see example).
Welding generator amperage out-
put must be at least twice the
motor’s running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amper-
age required for a 230 V, 1/4 HP mo-
tor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624
12-9. How Much Power Can Generator Supply?
1 Limit Load To 90% Of

Generator Output
1
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.
2 5 Second Rule
2
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-244 023 Page 57

12-10. Typical Connections To Supply Standby Power
! Have only qualified persons

perform these connections
according to all applicable
1 2 3 4 codes and safety practices.
Fused ! Properly install and ground
Utility Welding
Disconnect this equipment according to
Electrical Transfer Switch Generator
Switch its Owner’s Manual and na-
Service Output
(If Required) tional, state, and local codes.
Customer-supplied equipment
is required if generator will sup-
ply standby power during
emergencies or power out-
5
ages.
1 Utility Electrical Service
Essential
Loads 2 Transfer Switch (Double-Throw)
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is re-
stored.
Install correct switch (customer-
supplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customer-
supplied) if required by electrical
code.
4 Welding Generator Output
Generator output voltage and wir-
ing must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low volt-
age and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the prem-
ises. If generator does not produce
enough output to meet all require-
ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 12-4).
OM-244 023 Page 58

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

OM-244 023 Page 59
SECTION 13 − PARTS LIST
Hardware is common and not
available unless listed.
15
3
16
17
2
1
18
19
14
7
6 20
13
5 12
11 21
10
4
8 22
9
13
118 23
126 24
25
115
125 124
123
121
119 117
120
116 − Figure 13-2
110
111
112
113
114 131
122 − Figure 13-3
Figure 13-1. Main Assembly

OM-244 023 Page 60
36 62
37
35 61
34 60 63
64
56 65
59
33 58
38 54 55 57
52 53
32 31
30 39
29 50 51
28 47 130
27
49 66
46 48
67
26 68
129
109 40 44 45 69
127 71 70
41 128 72
43 73
74
83 75
78
102 82 76
99 80 77
103 79
100 104 81
91
84
101 85 90 92
105 98 − Figure 13-5 89
88
86 87
93
106
107
108
96 94
97 95
907 157 00 11395−01 / 907 157 00 11395−02
OM-244 023 Page 61

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 13-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . 189824 . . Panel, Gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 189828 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 206601 . . Panel, Engine Extension LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . . . 208277 . . Reactor, AC Environmental Rda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 038620 . . Link, Jumper Term Blk 30 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 1T . . . . . 189549 . . Block, Term Assy Standard W/Clamp (includes) . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 038621 . . . . Block, Term 30 Amp 4 Pole Frict Term Str Both Side . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 081499 . . . . Bracket, Mtg Strip Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 138027 . . . . Edge Trim, Style Tl750−b2x1/16 Black W/Clips 3.750 . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 020225 . . . . Clamp, Nyl .875 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . 1
. . . 8 . . SR4, SR5 . . 035704 . . Rectifier, Integ Bridge 40 Amp 800 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . CB4 . . . . 045061 . . Circuit Breaker, Auto Reset 24vdc 7 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 206352 . . Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . T1 . . . . . 205636 . . Transformer, W/Brkt Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 201697 . . Pan, Reactor And Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 173352 . . Extrusion, Rubber (order by ft.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 244057 . . Firewall, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 194485 . . Hose, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 189764 . . Air Cleaner, Intake (Engine) (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192938 . . . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192939 . . . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206556 . . Pipe, Air Cleaner Intake Deutz (Turbo Hose To Air Cleaner Hose) . . . . . 1
. . . 17 . . . . . . . . . . . . . . 189763 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 206351 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . ♦209612 . . Lever, Switch Lockout Disconnect Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . ♦209597 . . Bracket, Mtg Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . ♦209611 . . Switch, Disc Battery 2P 6−36 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 196220 . . Bracket, Holddown Fuel Tank Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 192362 . . Bracket, Mtg Nyl 1/2 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 209094 . . Bracket, Mtg Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . +206603 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 192041 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . ♦143915 . . Mount, Sgl Stud 1.5 Dia X 1.000 Lg .312−18 Stud . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . ♦205702 . . Bracket, Mtg Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . ♦205749 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . ♦603767 . . Cap, Weather Exhaust No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . ♦010875 . . Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 35 . . . . . . . . . . . . ♦205712 . . Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . ♦205748 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 105734 . . Pipe, Muffler Extension Elbow 1.750 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 222513 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 248464 . . Manifold, Exhaust Muffler Bf4m2011 Deutz . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 213896 . . Spacer, Stl 1.250 X.375 .531 Hole Dia (Muffler) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 202633 . . Support, Cover E−coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . 191577 . . Guard, Starter Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 191809 . . Bracket, Mtg Engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 251537 . . Hose Assy, Air W/ 3/4 In Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 237005 . . Engine, Deutz Dsl Elec TD2011L04w (includes) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMR Module (Supplied with engine from Deutz) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193256 . . . . Adapter, Engine Deutz 1011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 195748 . . . . Flywheel, Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 195745 . . . . Switch, Pressure Oil 1.5 Bar Nc Cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067265 . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-244 023 Page 62
Item Dia. Part
Figure 13-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . . . *066217 . . . . Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 208041 . . Spacer, Stl .323 Id X .625 Od X .141 Thk (Alternator) . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193230 . . Sender, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 194403 . . Adaptor, Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . GLOW PLUG . 190059 . . Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . *207808 . . Belt, V .375 X 45.125 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 207203 . . Fan, Engine Cooling 18.000 Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 208042 . . Spacer, Stl .800id X 1.188od X .090 Thk (Fan Hub Bolt) . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 239515 . . Extension, Hydraulic 37 Deg Flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 209633 . . Hose, Tubing Oil Assyw/Fittings 27.040lg . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 51 . . . . . . . . . . . . . . 240354 . . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 52 . . . . . . . . . . . . . . 239504 . . Guard, Fan LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . 239503 . . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . . 239501 . . Cooler, Oil Engine/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . 209623 . . Ftg, Brs Adapter Long 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 239502 . . Upright, Rear Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 201006 . . Bolt, J Stl .312−18 X 7.750 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 58 . . . . BATT . . . . 190897 . . Battery, Stor 12v 650 Crk 110 Rsv Gp 24 Maint Free . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 108081 . . Terminal Protector, Battery Post Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 60 . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 203430 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . +239516 . . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 6
. . . 66 . . . . . . . . . . . . . +206602 . . Panel, Engine Extension R.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 239505 . . Guard, Fan RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 6
. . . 69 . . . . . . . . . . . . . . 208024 . . Pulley, Fan Assy W/Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 206613 . . Bracket, Mtg Fan/Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 199849 . . Screw, 625−11x4.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 72 . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 73 . . . . . . . . . . . . . . 191812 . . Bracket, Mtg Engine R.h. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 071890 . . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 75 . . . . . . . . . . . . . . 071730 . . Tubing, Stl .875 Od X12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 76 . . . . . . . . . . . . . . 083476 . . Mount, Eng/Gen Nprn .875id X 2.500od X 2.000 60 Dur . . . . . . . . . . . . . . 4
. . . 77 . . . . . . . . . . . . . . 135205 . . Nut, 625−11 .94hex .77h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 176529 . . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.666
. . . 81 . . . . . . . . . . . . . . 176528 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 1/2 Npt . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . . 173336 . . Ftg, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . 066298 . . Ring (Oil Drain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 239542 . . Bracket, Mtg Fuel Filter/Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . . . . . 232968 . . Base, Fuel Filter Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . *192744 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 199383 . . Hose, Sae .312 Id X .560 Od X 8.000 (Fuel Filter To Fuel Pump) . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 191819 . . Hose, Sae .312 Id X .560 Od X 14.000 (Fuel Tank To Fuel Filter) . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 156733 . . . . Nut, 250−28 .44hex .13h Stl Pld Sem Cone Wshr.51d . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . . 190992 . . Keeper, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . . 085963 . . Spring, Ext .375 Od X .041 Wire X 2.000 (ForSafety Latch) . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . . 206604 . . Channel, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . . 199592 . . Latch, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . . . 206464 . . Label, Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . +200 989 . . Door, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . 189 975 . . Hinge, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OM-244 023 Page 63
Item Dia. Part
Figure 13-1. Main Assembly (Continued)
. . . 94 . . . . . . . . . . . . . 208 141 . . Stop, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 95 . . . . . . . . . . . . . 189 826 . . Panel, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 97 . . . . . . . . . . . . . +189827 . . Panel, Gen Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . . . . . Figure 13-5 . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 218087 . . Tank, Fuel (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 101 . . . . . . . . . . . . . 189912 . . . . Ftg, Stl Barbed Elbow W/.047in Orifice Zinc Pld . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . . . 189909 . . . . Ftg, Stand Pipe Hose .250 X 9.265lg 90 Deg Zinc . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . . 189913 . . . . Ftg, Stl Barbed Elbow Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . . . . . . . . . 190142 . . . . Sender, Fuel Gauge 9.750 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . . 189910 . . . . Ftg, Stand Pipe Hose .3125 X 9.260lg 90 Deg Zinc . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . . . . . . . . . . . 181572 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196219 . . Hose, Sae .250 Id X .500 Od X 26.000 (Fuel Return Line) . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . . . 191446 . . Extrusion, Rubber w/Adhesive 1.000 x 1.000 (order by ft.) . . . . . . . . . . . . 6ft
. . 109 . . . . . . . . . . . . . 233088 . . Label, Danger Using A Generator Indoors Can Kill You In Minutes . . . . . 1
. . 110 . . . . . . . . . . . . +212224 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . . . . . . . . . . . . 191897 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 112 . . . . . . . . . . . . . 224266 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 113 . . . . . . . . . . . . . 212046 . . Label, Manufacturing Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 114 . . . . R3 . . . . . 189699 . . Resistor, WW Tap 375 W 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . 1
. . 115 . . . . . . . . . . . . . 218086 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 116 . . . . . . . . . Figure 13-2 . . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 117 . . . . . . . . . . . . . 189731 . . Firewall, Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 118 . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 119 . . . . . . . . . . . . . 182496 . . Term Assy, Pwr Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 120 . . . . . . . . . . . . . 244139 . . Box, Starting Panel Rr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 121 . . . . . . . . . . . . . 206609 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 122 . . . . . . . . . Figure 13-3 . . Panel, Front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 123 . . . . . . . . . . . . . 191448 . . Cover, Top Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 124 . . . . . . . . . . . . . 244086 . . Main Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 125 . . . PC1 . . . . 244098 . . Module, Field Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 126 . . . . . . . . . . . . . 244095 . . Bracket, Mtg Box Fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 127 . . . . . . . . . . . . . 195746 . . Sender, Coolant Temp & 130c Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 128 . . . . . . . . . . . . . 239641 . . Ftg, Adapter Oil Temperature Sender/Switch . . . . . . . . . . . . . . . . . . . . . . . 1
. . 129 . . . . . . . . . . . . . 209765 . . Ftg, Pipe Stl Elbow Adapter 90dg 3/4 Sae-jic- . . . . . . . . . . . . . . . . . . . . . . . 1
. . 130 . . . . . . . . . . . . . 210250 . . Hose Assy, Oil W/Fittings 3/4 X 15.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 131 . . . . . . . . . . . . . 233953 . . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 239704 . . Harness, Lead Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 238650 . . Label, Hour/Fuel Meter Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 212048 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . ♦195118 . . Kit, Lock-Out Vandalism (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209238 . . . . Door, Access Rh W/Om Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209240 . . . . Door, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209236 . . . . Tab, Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209241 . . . . Mount, Access Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209242 . . . . Mount, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦189975 . . . . Hinge, Door Access 180 Deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . ♦155146 . . . . Sponge, Nprn .060 X 1.000 Wide X 4.000 Sce 41 Close . . . . . . . . . . . . 3
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts. ♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-244 023 Page 64
6
4 7
8 9
10
2 11
1
12
13
14
15
20
16
17
18
19
Ref. 907 157 00 11395−03
Figure 13-2. Control Box Assembly
Item Dia. Part

Figure 13-2. Control Box Assembly − (Figure 13-1 Item 116)
. . . 1 . . . F1, F2 . . . 085874 .. Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . . 046432 .. Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . 134201 .. Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 3
. . . 4 . . . . PC9 . . . . 192224 .. Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 201077 .. Control Box, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 201078 .. Control Box, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . CR8 . . . . 197325 .. Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . CR3 . . . . 173069 .. Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . CR1 . . . . 214876 .. Relay, Encl 6 vdc spst 35A/14 vdc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 C1/D1,C8/D8,D12 189701 .. Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 11 . . . . . . . . . . . . . +201079 .. Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 239512 .. Label, Layout Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . CB10,CB16 . 190374 .. Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . CR5 . . . . 223710 .. Relay, Encl 12vdc Dpst−no 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . SR1 . . . . 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 189701 .. Diode/Capacitor Board (One in wiring harness not used in this unit) . . . . 1
. . . 17 . . . . . C9 . . . . . 087110 .. Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 177136 .. Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . CR10 . . . . 113247 .. Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR16 . . . . 244103 .. Relay, Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-244 023 Page 65

Item Dia. Part
Figure 13-2. Control Box Assembly − (Continued)
. . . . . . . . . . . . . . . . . . . . 206736 . . Harness, Control Box, Weld Control LH (includes) . . . . . . . . . . . . . . . . . . . 1

. . . 20 . CB11, CB12,CB13 139266 . . . . Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . 3
. . . . . . . . . . RC3 . . . . 158466 . . . . Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . 1
. . . . . . . . . . RC1 . . . . 135133 . . . . Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 242629 . . Harness, Engine Deutz TD2011L04w (includes) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 083432 . . . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S2 . . . . . 021467 . . . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located on front panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 177859 . . . . Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113247 . . . . Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . S10 . . . . 206624 . . . . Switch, Tgl Sptt 6a 125vac (On)−on−(On)Spd Term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located on front panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 189701 . . . . Diode/Capacitor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 214932 . . . . Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 156734 . . . . Nut, 010−32 .31hex .13h Stl Pld Sem Cone Wshr.38d . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 214876 . . . . Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 139266 . . . . Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197325 . . . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 240075 . . . . Connector, Housing Splash Proof 90 Vers . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 240076 . . . . Connector, Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 240074 . . . . Seal, Plug Single Wire (5mm Hole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . 240071 . . . . Plug, Cavity 2,5mm For 5,4mm Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . 240098 . . . . Connector, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 240099 . . . . Cap, Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 240100 . . . . Clamp, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 240077 . . . . Connector, Housing 2p Junior−timer Geh . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215192 . . . . Conn, Rect 2p Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 240104 . . . . Connector, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 240081 . . . . Connector, Rnd 7p 1.5mm Bu−ste Kpl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 240082 . . . . Strain Relief, 90grd Abdeckkappe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 240442 . . . . Connector, Housing Junior Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 240076 . . . . Connector, Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip, Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
♦Optional
*Recommended Spare Parts.
OM-244 023 Page 66

4
3
Hardware is common and
not available unless listed.
2
1 5
6
10
7
8
9
29 11
28
12
27
26
13
25
24
23
22 17
18
19
21 14
20
15
16 Ref: 803 457-E
Figure 13-3. Panel, Front w/Components
Item Dia. Part

Figure 13-3. Panel, Front w/Components (Figure 13-1 Item 122)
... 1 .............. 239132 .. Plate, Screened Ident Control (Order By Model And Serial Number) . . . . 1
... 2 .............. 238616 .. Panel, Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . CT3 . . . . 209274 .. Xfmr, Current (Meters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . S3 . . . . . 244087 .. Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-244 023 Page 67

Item Dia. Part
Figure 13-3. Panel, Front w/Components (Continued)
. . . . . . . . . . . . . . . . . . . . 192558 . . Harness, Range Switch (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . RC6 . . . . 148389 . . . . Conn, Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206809 . . Harness, Weld Control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . S6 . . . . . 193234 . . . . Switch, Rotary 6 Position Gold Contacts . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197527 . . . . Guard, Circuit Breaker (For S6 − Not Included w/Harness) . . . . . . . . . . 1
. . . 7 . . . . . S5 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196603 . . . . Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG14 . . . 141450 . . . . Conn, Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip,Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG10 . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . CB5 . . . . 139266 . . . . Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB6 . . . . 139266 . . . . Supplementary Protector, Man Reset 1p 15a 250vac . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon .221 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . PC6 . . . . 192995 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S1 . . . . . 217680 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 207073 . . Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201244 . . Washer, tooth.728idx1.166odx.050t stl pld int.688 . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . S2 . . . . . 021467 . . Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term (Included In Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness, See Figure Figure 13-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . Figure 13-4 . . Auxiliary Power Group
. . . 14 . . . . . . . . . . . . . . 244138 . . Panel, Mtg Terminal Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . PC4, PC5 . . 189744 . . Circuit Card Assembly, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 8
. . . 17 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 19 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . FUEL/HM . . 232112 . . Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . BAT . . . . 193228 . . Meter, Volt DC 8 − 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . TEMP . . . 217084 . . Gauge, Coolant Temp 0− 300 Deg F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . OIL . . . . . 217083 . . Gauge, Pressure Oil 0−100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . A1 . . . . . 164873 . . Meter, Amp AC/DC 0− 500 0−600 Dc Scale 2.5 In . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . V1 . . . . . 164874 . . Meter, Volt AC/DC 0− 100 Scale 2.5 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 189161 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 097924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215207 . . Harness, Unit Weld Control − CV (includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114063 . . . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . . 193184 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 147992 . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . . 158465 . . . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 088731 . . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 135873 . . . . Clip, Conduit Convoluted 1/2 In 6.35mm Mtg Hole . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 187654 . . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196602 . . . . Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . 059712 . . Clip, Component .437 Dia Mtg Adh Back . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 024103 . . Blank, Snap−in Nyl .750 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 120304 . . Blank, Snap−in Nyl .250 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 025234 . . Plug, Str Grd 2p3w 15a 250v *6−15p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-244 023 Page 68

245 341
Figure 13-4. Auxiliary Power Group, Export
Item Dia. Part

Figure 13-4. Auxiliary Power Group
. . . 1 . . . . . . . . . . . . . . 244134 . . Panel, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 139041 . . Bushing, Strain Relief .450/.709 Id X1.115 Mtg Hole . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . 246865 . . Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 188719 . . Block, Term 40 Amp 12 Pole Screw Term . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8
... 9
. . . 10 . . . . . . . . . . . . . . 093996 . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . 2049100011219 . . Cable, Power 8/C 2−14ga 6−18ga Nspr 11219 . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . 0937270011219 . . Label, Terminal Strip Cbi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
OM-244 023 Page 69

Hardware is common and
not available unless listed.
11
14
15
13 16
10 12 17
9
8 18
19
7 20
6
5
3 21 34
4 22
2 23
1 25 24
26
27
28
29
30
31
32
33
803 327
Figure 13-5. Generator
Item Dia. Part

Figure 13-5. Generator (Figure 13-1 Item 98)
. . . 1 . . . . . . . . . . . . . . 132053 . . Screw, 375−16x1.50 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . 2 . . . . . . . . . . . . . . 183387 . . Washer, Cone .380idx .860odx.109t Stl Pld 4000lbs . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 195911 . . Endbell, Gen (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 143220 . . . . O-Ring 2.859 ID X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . AUX STATOR . 201099 . . Stator, Exciter/Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . STATOR . . +244068 . . Stator, Weld Assy Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 190197 . . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 172674 . . Spring, Ext .240 Od X .041 Wire X 3.500 Pld . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 039207 . . Baffle, Air Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . ROTOR . . . 210446 . . Rotor, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 024617 . . . . Ring, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 210447 . . . . Fan, Rotor Assy Generator (Segmented) (includes) . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 210332 . . . . . . Plate, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 206242 . . . . . . Fan, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . . 049026 . . . . . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 18 . . . . . . . . . . . . . . 083883 . . . . . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . 10
. . . 19 . . . . . . . . . . . . . . 080389 . . . . . . Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . 8
. . . 20 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 4
. . . 21 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 22 . . . . . . . . . . . . . . 191579 . . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 6
. . . 24 . . . . . . . . . . . . . . 172555 . . Screw, M10−1.5x 50 Hex Hd−pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OM-244 023 Page 70

Item Dia. Part
Figure 13-5. Generator (Continued)
. . . 25 . . . . . . . . . . . . . . 602159 .. Screw, 312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . . . . . 6

. . . 26 . . . . . . . . . . . . . . 604950 .. Screw, 312−18x2.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 27 . . . . . . . . . . . . . . 602211 .. Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 4
. . . 28 . . . . . . . . . . . . . . 139341 .. Washer, Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 29 . . . . . . . . . . . . . *190823 .. Brush, Contact Elect .250 X.500 X 1.250 Grd Ay . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 188560 .. Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 30 . . . . . . . . . . . . . . 189142 .. Brushholder, Generator (Brushes Not Included − See Item 29) . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 602242 .. Washer, Flat .375idx0.875odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 32 . . . . . . . . . . . . . . 602211 .. Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 604534 .. Screw, 312−18x1.25 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 34 . . . . . . . . . . . . . . 239759 .. Bracket, Mounting Magnetic Pickup Assy . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
OM-244 023 Page 71

Notes
Ref. AWS/ANSI A2.4
Welding Symbols
OM-244 023 Page 72

Effective January 1, 2011
(Equipment with a serial number preface of MB or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions 6. 90 Days — Parts
Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its * Accessory (Kits)
1-800-4-A-MILLER original retail purchaser that new Miller equipment sold after the
effective date of this limited warranty is free of defects in material
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
for your local and workmanship at the time it is shipped by Miller. THIS
Non-Electronic Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
Miller distributor. WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * M-Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS. * MIG Guns and Subarc (SAW) Guns
* Remote Controls and RFCS-RJ45
Within the warranty periods listed below, Miller will repair or replace
any warranted parts or components that fail due to such defects in * Replacement Parts (No labor)
Your distributor also gives * Roughneck Guns
you ... material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will * Spoolmate Spoolguns
Service provide instructions on the warranty claim procedures to be Miller’s True Blue® Limited Warranty shall not apply to:
You always get the fast, followed.
1. Consumable components; such as contact tips,
reliable response you Miller shall honor warranty claims on warranted equipment listed cutting nozzles, contactors, brushes, relays, work
need. Most replacement below in the event of such a failure within the warranty time station table tops and welding curtains, or parts that
parts can be in your periods. All warranty time periods start on the delivery date of the fail due to normal wear. (Exception: brushes and
hands in 24 hours. equipment to the original end-user purchaser, and not to exceed relays are covered on all engine-driven products.)
one year after the equipment is shipped to a North American
Support distributor or eighteen months after the equipment is shipped to an 2. Items furnished by Miller, but manufactured by others,
Need fast answers to the International distributor. such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
tough welding questions? 1. 5 Years Parts — 3 Years Labor
Contact your distributor. 3. Equipment that has been modified by any party other than
* Original main power rectifiers only to include SCRs, Miller, or equipment that has been improperly installed,
The expertise of the diodes, and discrete rectifier modules improperly operated or misused based upon industry
distributor and Miller is 2. 3 Years — Parts and Labor standards, or equipment which has not had reasonable
there to help you, every * Engine Driven Welding Generators and necessary maintenance, or equipment which has
step of the way. (NOTE: Engines are warranted separately by the been used for operation outside of the specifications for
engine manufacturer.) the equipment.
* Inverter Power Sources (Unless Otherwise Stated) MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Plasma Arc Cutting Power Sources USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
* Process Controllers TRAINED AND EXPERIENCED IN THE USE AND
* Semi-Automatic and Automatic Wire Feeders MAINTENANCE OF WELDING EQUIPMENT.
* Smith 30 Series Flowgauge and Flowmeter In the event of a warranty claim covered by this warranty, the
Regulators (No Labor) exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Transformer/Rectifier Power Sources replacement; or, where authorized in writing by Miller in
* Water Coolant Systems (Integrated) appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4) payment
3. 2 Years — Parts of or credit for the purchase price (less reasonable depreciation
* Auto-Darkening Helmet Lenses (No Labor) based upon actual use) upon return of the goods at customer’s risk
4. 1 Year — Parts and Labor Unless Specified and expense. Miller’s option of repair or replacement will be F.O.B.,
* Automatic Motion Devices Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized
* CoolBelt and CoolBand Blower Unit (No Labor) service facility as determined by Miller. Therefore no
compensation or reimbursement for transportation costs of any
* External Monitoring Equipment and Sensors
kind will be allowed.
* Field Options
(NOTE: Field options are covered for the remaining TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
warranty period of the product they are installed in, or
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
for a minimum of one year — whichever is greater.) DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
* Flowgauge and Flowmeter Regulators (No Labor) CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* RFCS Foot Controls (Except RFCS-RJ45) PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
* Fume Extractors OTHER LEGAL THEORY.
* HF Units ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* ICE Plasma Cutting Torches (No Labor) ANY IMPLIED WARRANTY, GUARANTY OR
* Induction Heating Power Sources, Coolers, and REPRESENTATION AS TO PERFORMANCE, AND ANY
Electronic Controls/Recorders REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Load Banks OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
* Motor Driven Guns (w/exception of Spoolmate MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
Spoolguns)
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
* PAPR Blower Unit (No Labor) FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
* Positioners and Controllers ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS
* Racks EXCLUDED AND DISCLAIMED BY MILLER.
* Running Gear/Trailers Some states in the U.S.A. do not allow limitations of how long an
* Spot Welders implied warranty lasts, or the exclusion of incidental, indirect,
* Subarc Wire Drive Assemblies special or consequential damages, so the above limitation or
* Water Coolant Systems (Non-Integrated) exclusion may not apply to you. This warranty provides specific
* Weldcraft-Branded TIG Torches (No Labor) legal rights, and other rights may be available, but may vary from
state to state.
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
5. 6 Months — Parts
to the extent that they may not be waived, the limitations and
* Batteries exclusions set out above may not apply. This Limited Warranty
* Bernard Guns (No Labor) provides specific legal rights, and other rights may be available,
* Tregaskiss Guns (No Labor) but may vary from province to province.
miller_warr 2011−01
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2011 Miller Electric Mfg. Co. 2011−01
OM-166 941C July 1999
Processes
Stick (SMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)

Cutting and Gouging
Description
Engine Driven Welding Generator
CBI 801D
(Per NSPR 10202)
Warranty
Effective January 1, 1999
(Equipment with a serial number preface of “KK” or newer)
This limited warranty supersedes all previous manufacturers Limited Warranty shall not apply to:
warranties and is exclusive with no other guarantees or
warranties expressed or implied. 1. Items furnished by manufacturer, but manufactured by
others, such as engines or trade accessories. These
LIMITED WARRANTY − Subject to the terms and conditions items are covered by the manufacturer’s warranty, if
below, warrants to its original retail purchaser that new any.
equipment sold after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is 2. Consumable components; such as contact tips, cutting
shipped from factory. THIS WARRANTY IS EXPRESSLY IN nozzles, contactors, relays, brushes, slip rings, or parts
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR that fail due to normal wear.
IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS. 3. Equipment that has been modified by any party other
than manufacturer, or equipment that has been
Within the warranty periods listed below, manufacturer will improperly installed, improperly operated or misused
repair or replace any warranted parts or components that fail based upon industry standards, or equipment which has
due to such defects in material or workmanship. not had reasonable and necessary maintenance, or
Manufacturer must be notified in writing within thirty (30) days equipment which has been used for operation outside of
of such defect or failure, at which time manufacturer will the specifications for the equipment.
provide instructions on the warranty claim procedures to be
followed. MANUFACTURER’S PRODUCTS ARE INTENDED FOR
PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL
Manufacturer shall honor warranty claims on warranted USERS AND PERSONS TRAINED AND EXPERIENCED IN
equipment listed below in the event of such a failure within the THE USE AND MAINTENANCE OF WELDING
warranty time periods. All warranty time periods start on the EQUIPMENT.
date that the equipment was delivered to the original retail
purchaser, or one year after the equipment is sent to the In the event of a warranty claim covered by this warranty, the
distributor. exclusive remedies shall be, at manufacturers option: (1)
repair; or (2) replacement; or, where authorized in writing by
1. 5 Years Parts − 3 Years Labor manufacturer in appropriate cases, (3) the reasonable cost
* Original main power rectifiers of repair or replacement at an authorized service station; or
(4) payment of or credit for the purchase price (less
2. 3 Years — Parts and Labor reasonable depreciation based upon actual use) upon return
of the goods at customer’s risk and expense. manufacturer’s
* Transformer/Rectifier Power Sources option of repair or replacement will be F.O.B., Factory at
* Plasma Arc Cutting Power Sources Appleton, Wisconsin, or F.O.B. at an authorized service
* Semi-Automatic and Automatic Wire Feeders facility as determined by manufacturer. Therefore no
* Engine Driven Welding Generators compensation or reimbursement for transportation costs of
(NOTE: Engines are warranted separately by the any kind will be allowed.
engine manufacturer.)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
3. 1 Year — Parts and Labor PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MANUFACTURER BE
* Motor Driven Guns (w/exception of Spoolmate 185) LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL
* Process Controllers OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Positioners and Controllers PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Automatic Motion Devices ANY OTHER LEGAL THEORY.
* Robots ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
* RFCS Foot Controls AND ANY IMPLIED WARRANTY, GUARANTY OR
* Water Coolant Systems REPRESENTATION AS TO PERFORMANCE, AND ANY
* HF Units REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Grids OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
* Spot Welders OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Load Banks OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
* SDX Transformers MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Running Gear/Trailers PURPOSE, WITH RESPECT TO ANY AND ALL
* Field Options EQUIPMENT FURNISHED BY MANUFACTURER IS
(NOTE: Field options are covered under the limited EXCLUDED AND DISCLAIMED BY MANUFACTURER.
warranty for the remaining warranty period of the Some states in the U.S.A. do not allow limitations of how long
product they are installed in, or for a minimum of one an implied warranty lasts, or the exclusion of incidental,
year — whichever is greater.) indirect, special or consequential damages, so the above
4. 6 Months — Batteries limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
5. 90 Days — Parts and Labor available, but may vary from state to state.
* MIG Guns/TIG Torches In Canada, legislation in some provinces provides for certain
* Plasma Cutting Torches additional warranties or remedies other than as stated
* Remote Controls herein, and to the extent that they may not be waived, the
limitations and exclusions set out above may not apply. This
* Accessory Kits Limited Warranty provides specific legal rights, and other
* Replacement Parts rights may be available, but may vary from province to
* Spoolmate 185 province.
brand_warr 9/99
OM-166 941C − 7/99
TABLE OF CONTENTS
Section No. Page No.
SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-4. Standards Booklet Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 2 − SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1. General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-2. Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-1. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-3. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 4 − INSTALLATION OR RELOCATION

4-1. Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-2. Exhaust Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-3. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-4. Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-5. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-6. Equipment Grounding Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-7. Weld Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-8. Remote Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-9. Air Compressor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-10. Ether Starting Aid (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 − AUXILIARY POWER

5-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-2. 120 Volt Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 6 − OPERATOR CONTROLS

6-1. Ampere Ranges Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6-2. Amperage & Voltage Adjustment Control . . . . . . . . . . . . . . . . . . . . . . . 16
6-3. Engine Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6-4. Remote Amperage & Voltage Control Switch . . . . . . . . . . . . . . . . . . . . 17
6-5. Output(Contactor) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-6. Service Engine Air Cleaner Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-7. Check Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-8. Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-9. Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-10. Magnetic Shutdown Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-11. Oil Temperature Gauge/Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-12. Oil Pressure Gauge/Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-13. Battery Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-14. Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-15. Broken Cooling Belt Shutdown Switch . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 7 − SEQUENCE OF OPERATION
7-1. Shielded Metal Arc Welding (SMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7-2. Gas Metal Arc (GMAW) And Flux Cored Arc Welding (FCAW) . . . . 19
7-3. Air Carbon Arc Cutting And Gouging (CAC-A) . . . . . . . . . . . . . . . . . . . 20
7-4. Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7-5. Air Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7-6. Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7-7. Stopping The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 8 − MAINTENANCE
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8-2. Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8-3. Fuel/Water Separator And Sludge Drain Plug . . . . . . . . . . . . . . . . . . . 26
8-4. Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8-5. Battery Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8-6. Maintenance-Free Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8-7. Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8-8. Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8-9. Brushes And Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-11. Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-12. Run-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Diagram 8-1. Load Bank Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Diagram 8-2. Resistance Grid Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9-2. Booster Battery Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9-3. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9-4. Circuit Board Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9-5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 10 − ELECTRICAL DIAGRAMS
Diagram 10-1. Circuit Diagram For Welding Generator . . . . . . . . . . . . . . . . . . 36
Figure 11-1A. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 11-1B. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 11-2. Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 11-3. Panel, Lower Front w/Components . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 11-4. Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 11-5. Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
LIST OF TABLES AND CHARTS
Table 3-1. Welding Generator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chart 3-1. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chart 3-2. Air Output Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chart 4-1. Fuel Consumption Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table 4-1. Weld Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chart 5-1. AC Power Curve For 120 Volt Terminals . . . . . . . . . . . . . . . . . . . . . 15
Table 7-1. Suggested Electrode Diameter For Amperage Range (CAC-A Only) 20
Table 7-2. Flow Of Free Air (CFM) Through Orifices Of Various Diameters 21
Table 7-3. Approximate Air Consumption (Cubic Feet) Required To Operate
Various Pneumatic Equipment At Pressure Range 70-90 P.S.I.G. . . . . . . . . 22
Table 8-1. Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 8-2. Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table 9-1. Weld/Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Table 9-2. Auxiliary Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 9-3. Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 9-4. Air Compressor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1. INTRODUCTION from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
We learn by experience. Learning safety through per-
sonal experience, like a child touching a hot stove is Avoid oily or greasy clothing. A spark may ignite them.
harmful, wasteful, and unwise. Let the experience of
Hot metal such as electrode stubs and workpieces
others teach you.
should never be handled without gloves.
Safe practices developed from experience in the use of
Medical first aid and eye treatment. First aid facilities
welding and cutting are described in this manual. Re-
and a qualified first aid person should be available for
search, development, and field experience have
each shift unless medical facilities are close by for im-
evolved reliable equipment and safe installation, opera-
mediate treatment of flash burns of the eyes and skin
tion, and servicing practices. Accidents occur when
burns.
equipment is improperly used or maintained. The rea-
son for the safe practices may not always be given. Ear plugs should be worn when working on overhead or
Some are based on common sense, others may require in a confined space. A hard hat should be worn when
technical volumes to explain. It is wiser to follow the others work overhead.
rules. Flammable hair preparations should not be used by per-
Read and understand these safe practices before at- sons intending to weld or cut.
tempting to install, operate, or service the equipment. B. Toxic Fume Prevention
Comply with these procedures as applicable to the par-
ticular equipment used and their instruction manuals, Severe discomfort, illness or death can result from
for personal safety and for the safety of others. fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
Failure to observe these safe practices may cause seri- with adequate ventilation as described in ANSI Stan-
ous injury or death. When safety becomes a habit, the dard Z49.1 listed in Standards Index. NEVER ventilate
equipment can be used with confidence. with oxygen.
These safe practices are divided into two Sections: Lead -, cadmium -, zinc -, mercury -, and beryllium-bear-
1-General Precautions, common to arc welding and cut- ing and similar materials, when welded (or cut) may pro-
ting; and 2-Arc Welding (and Cutting) (only). duce harmful concentrations of toxic fumes. Adequate
Reference standards: Published Standards on safety local exhaust ventilation must be used, or each person
are also available for additional and more complete pro- in the area as well as the operator must wear an air-sup-
cedures than those given in this manual. They are listed plied respirator. For beryllium, both must be used.
in the Standards Index in this manual. ANSI Z49.1 is the Metals coated with or containing materials that emit
most complete. toxic fumes should not be heated unless coating is re-
The National Electrical Code, Occupational Safety and moved from the work surface, the area is well ventilated
Health Administration, local industrial codes, and local and, if necessary, while wearing an air-supplied respira-
inspection requirements also provide a basis for equip- tor.
ment installation, use, and service. Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respira-
1-2. GENERAL PRECAUTIONS tor.
Different arc welding processes, electrode alloys, Gas leaks in a confined space should be avoided.
and fluxes can produce different fumes, gases, and
Leaked gas in large quantities can change oxygen con-
radiation levels. In addition to the information in centration dangerously. Do not bring gas cylinders into a
this manual, be sure to consult flux and electrode confined space.
manufacturers Material Safety Data Sheets
(MSDSs) for specific technical data and precaution- Leaving confined space, shut OFF gas supply at source
ary measures concerning their material. to prevent possible accumulation of gases in the space if
downstream valves have been accidentally opened or
A. Burn Prevention
left open. Check to be sure that the space is safe before
Wear protective clothing-gauntlet gloves designed for re-entering it.
use in welding, hat, and high safety-toe shoes. Button
Vapors from chlorinated solvents can be decomposed
shirt collar and pocket flaps, and wear cuffless trousers
by the heat of the arc (or flame) to form PHOSGENE, a
to avoid entry of sparks and slag.
highly toxic gas, and other lung and eye irritating prod-
Wear helmet with safety goggles and glasses with side ucts. The ultraviolet (radiant) energy of the arc can also
shields underneath, appropriate filter lenses or plates decompose trichloroethylene and perchloroethylene
(protected by clear cover glass). This is a MUST for vapors to form phosgene. DO NOT WELD or cut where
welding or cutting, (and chipping) to protect the eyes solvent vapors can be drawn into the welding or cutting
OM-166 941 Page 1
atmosphere or where the radiant energy can penetrate ment as recommended in A6.0. Waterfilling just below
to atmospheres containing even minute amounts of working level may substitute for inerting.
trichloroethylene or perchloroethylene. A container with unknown contents should be cleaned
C. Fire and Explosion Prevention (see preceding paragraph). Do NOT depend on sense
of smell or sight to determine if it is safe to weld or cut.
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated mate- Hollow castings or containers must be vented before
rial; misuse of compressed gases and cylinders; and welding or cutting. They can explode.
short circuits. Explosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
BE AWARE THAT flying sparks or falling slag can pass
as gasoline).
through cracks, along pipes, through windows or doors,
and through wall or floor openings, out of sight of the D. Compressed Gas Equipment
goggled operator. Sparks and slag can fly 35 feet. Standard precautions. Comply with precautions in this
To prevent fires and explosion: manual, and those detailed in CGA Standard P-1, SAFE
HANDLING OF COMPRESSED GASES IN CYLIN-
Keep equipment clean and operable, free of oil, grease, DERS, listed 11 in Standards Index.
and (in electrical parts) of metallic particles that can
1. Pressure Regulators
cause short circuits.
Regulator relief valve is designed to protect only the
If combustibles are in area, do NOT weld or cut. Move regulator from overpressure; it is not intended to protect
the work if practicable, to an area free of combustibles. any downstream equipment. Provide such protection
Avoid paint spray rooms, dip tanks, storage areas, ven- with one or more relief devices.
tilators. If the work cannot be moved, move comb-
ustibles at least 35 feet away out of reach of sparks and Never connect a regulator to a cylinder containing gas
heat; or protect against ignition with suitable and snug- other than that for which the regulator was designed.
fitting, fire-resistant covers or shields. Remove faulty regulator from service immediately for
repair (first close cylinder valve). The following symp-
Walls touching combustibles on opposite sides should
toms indicate a faulty regulator:
not be welded on (or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or Leaks-if gas leaks externally.
shields. Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.
Fire watcher must be standing by with suitable fire extin- Faulty Gauge-if gauge pointer does not move off stop
guishing equipment during and for some time after weld- pin when pressurized, nor returns to stop pin after pres-
ing or cutting if: sure release.
a. appreciable combustibles (including building Repair. Do NOT attempt to repair. Send faulty regula-
construction) are within 35 feet tors for repair to manufacturer’s designated repair cen-
b. appreciable combustibles are further than 35 ter, where special techniques and tools are used by
feet but can be ignited by sparks trained personnel.
2. Cylinders
c. openings (concealed or visible) in floors or walls
within 35 feet may expose combustibles to Cylinders must be handled carefully to prevent leaks
sparks and damage to their walls, valves, or safety devices:
d. combustibles adjacent to walls, ceilings, roofs, Avoid electrical circuit contact with cylinders including
or metal partitions can be ignited by radiant or third rails, electrical wires, or welding circuits. They can
conducted heat. produce short circuit arcs that may lead to a serious ac-
cident. (See 1-3C.)
Hot work permit should be obtained before operation to
ICC or DOT marking must be on each cylinder. It is an
ensure supervisor’s approval that adequate precau-
assurance of safety when the cylinder is properly han-
tions have been taken.
dled.
After work is done, check that area is free of sparks, Identifying gas content. Use only cylinders with name of
glowing embers, and flames. gas marked on them; do not rely on color to identify gas
An empty container that held combustibles, or that can content. Notify supplier if unmarked. NEVER DEFACE
produce flammable or toxic vapors when heated, must or alter name, number, or other markings on a cylinder. It
never be welded on or cut, unless container has first is illegal and hazardous.
been cleaned as described in AWS Standard A6.0, Empties: Keep valves closed, replace caps securely;
listed 7 in Standards Index. mark MT; keep them separate from FULLS and return
This includes: a thorough steam or caustic cleaning (or promptly.
a solvent or water washing, depending on the combusti- Prohibited use. Never use a cylinder or its contents for
ble’s solubility) followed by purging and inerting with ni- other than its intended use, NEVER as a support or
trogen or carbon dioxide, and using protective equip- roller.
OM-166 941 Page 2
Locate or secure cylinders so they cannot be knocked outlet away from people and sources of ignition. Wipe
over. with a clean lintless cloth.
Passageways and work areas. Keep cylinders clear of Match regulator to cylinder. Before connecting, check
areas where they may be struck. that the regulator label and cylinder marking area, and
that the regulator inlet and cylinder outlet match.
Transporting cylinders. With a crane, use a secure sup- NEVER CONNECT a regulator designed for a particular
port such as a platform or cradle. Do NOT lift cylinders gas or gases to a cylinder containing any other gas.
off the ground by their valves or caps, or by chains,
slings, or magnets. Tighten connections. When assembling threaded con-
nections, clean and smooth seats where necessary.
Do NOT expose cylinders to excessive heat, sparks, Tighten. If connection leaks, disassemble, clean, and
slag, and flame, etc. that may cause rupture. Do not al- retighten using properly fitting wrench.
low contents to exceed 130°F. Cool with water spray
where such exposure exists. Adapters. Use a CGA adapter (available from your sup-
plier) between cylinder and regulator, if one is required.
Protect cylinders particularly valves from bumps, falls, use two wrenches to tighten adapter marked RIGHT
falling objects, and weather. Replace caps securely and LEFT HAND threads.
when moving cylinders.
Regulator outlet (or hose) connections may be identified
Stuck valve. Do NOT use a hammer or wrench to open a by right hand threads for oxygen and left hand threads
cylinder valve that can not be opened by hand. Notify (with grooved hex on nut or shank) for fuel gas.
your supplier.
5. Pressurizing Steps:
Mixing gases. Never try to mix any gases in a cylinder.
Drain regulator of residual gas through suitable vent be-
Never refill any cylinder. fore opening cylinder (or manifold valve) by turning ad-
justing screw in (clockwise). Draining prevents exces-
Cylinder fittings should never be modified or ex- sive compression heat at high pressure seat by allowing
changed. seat to open on pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
3. Hose
Stand to side of regulator while opening cylinder valve.
Prohibited use. Never use hose other than that de-
signed for the specified gas. A general hose identifica- Open cylinder valve slowly so that regulator pressure in-
tion rule is: red for fuel gas, green for oxygen, and black creases slowly. When gauge is pressurized (gauge
for inert gases. reaches regulator maximum) leave cylinder valve in fol-
lowing position: For oxygen, and inert gases, open fully
Use ferrules or clamps designed for the hose (not ordi- to seal stem against possible leak. For fuel gas, open to
nary wire or other substitute) as a binding to connect less than one turn to permit quick emergency shutoff.
hoses to fittings.
Use pressure charts (available from your supplier) for
No copper tubing splices. Use only standard brass fit- safe and efficient, recommended pressure settings on
tings to splice hose. regulators.
Avoid long runs to prevent kinks and abuse. Suspend Check for leaks on first pressurization and regularly
hose off ground to keep it from being run over, stepped there-after. Brush with soap solution (capfull of Ivory
on, or otherwise damaged. Liquid* or equivalent per gallon of water). Bubbles indi-
cate leak. Clean off soapy water after test; dried soap is
Coil excess hose to prevent kinks and tangles. combustible.
Protect hose from damage by sharp edges, and by E. User Responsibilities
sparks, slag, and open flame.
Remove leaky or defective equipment from service im-
Examine hose regularly for leaks, wear, and loose con- mediately for repair. See User Responsibility statement
nections. Immerse pressured hose in water; bubbles in- in equipment manual.
dicate leaks.
F. Leaving Equipment Unattended
Repair leaky or worn hose by cutting area out and splic-
Close gas supply at source and drain gas.
ing (1-2D3). Do NOT tape.
G. Rope Staging-Support
4. Proper Connections
Rope staging-support should not be used for welding or
Clean cylinder valve outlet of impurities that may clog cutting operation; rope may burn.
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing *Trademark of Proctor & Gamble.
OM-166 941 Page 3
1-3. ARC WELDING Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
Comply with precautions in 1-1, 1-2, and this section.
Arc Welding, properly done, is a safe process, but a Others working in area. See that all persons are wearing
careless operator invites trouble. The equipment carries flash goggles.
high currents at significant voltages. The arc is very Before starting to weld, make sure that screen flaps or
bright and hot. Sparks fly, fumes rise, ultraviolet and in- bay doors are closed.
frared energy radiates, weldments are hot, and com-
pressed gases may be used. The wise operator avoids B. Toxic Fume Prevention
unnecessary risks and protects himself and others from Comply with precautions in 1-2B.
accidents. Precautions are described here and in stan-
dards referenced in index. Generator engine exhaust must be vented to the out-
side air. Carbon monoxide can kill.
A. Burn Protection
C. Fire and Explosion Prevention
Comply with precautions in 1-2.
Comply with precautions in 1-2C.
The welding arc is intense and visibly bright. Its radiation
Equipment’s rated capacity. Do not overload arc weld-
can damage eyes, penetrate lightweight clothing, reflect
ing equipment. It may overheat cables and cause a fire.
from light-colored surfaces, and burn the skin and eyes.
Skin burns resemble acute sunburn, those from gas- Loose cable connections may overheat or flash and
shielded arcs are more severe and painful. DON’T GET cause a fire.
BURNED; COMPLY WITH PRECAUTIONS. Never strike an arc on a cylinder or other pressure ves-
1. Protective Clothing sel. It creates a brittle area that can cause a violent rup-
ture or lead to such a rupture under rough handling.
Wear long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As nec- D. Compressed Gas Equipment
essary, use additional protective clothing such as Comply with precautions in 1-2D.
leather jacket or sleeves, flame-proof apron, and fire-re-
sistant leggings. Avoid outer garments of untreated cot- E. Shock Prevention
ton. Exposed hot conductors or other bare metal in the weld-
Bare skin protection. Wear dark, substantial clothing. ing circuit, or in ungrounded, electrically-HOT equip-
Button collar to protect chest and neck and button pock- ment can fatally shock a person whose body becomes a
ets to prevent entry of sparks. conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR
TOUCH a wet surface when welding, without suitable
2. Eye and Head Protection protection.
Protect eyes from exposure to arc. NEVER look at an To protect against shock:
electric arc without protection.
Wear dry insulating gloves and body protection. Keep
Welding helmet or shield containing a filter plate shade body and clothing dry. Never work in damp area without
no. 12 or denser must be used when welding. Place over adequate insulation against electrical shock. Stay on a
face before striking arc. dry duckboard, or rubber mat when dampness or sweat
Protect filter plate with a clear cover plate. can not be avoided. Sweat, sea water, or moisture be-
tween body and an electrically HOT part or grounded
Cracked or broken helmet or shield should NOT be metal reduces the electrical resistance, and could en-
worn; radiation can pass through to cause burns. able dangerous and possibly lethal currents to flow
Cracked, broken, or loose filter plates must be replaced through the body.
IMMEDIATELY. Replace clear cover plate when broken, A voltage will exist between the electrode and any con-
pitted, or spattered. ducting object in the work circuit. Examples of conduct-
Flash goggles with side shields MUST be worn under ing objects include, but are not limited to, buildings, elec-
the helmet to give some protection to the eyes should trical tools, work benches, welding power source cases,
the helmet not be lowered over the face before an arc is workpieces, etc. Never touch the electrode and any
struck. Looking at an arc momentarily with unprotected metal object unless the welding power source is
eyes (particularly a high intensity gas-shielded arc) can off.
cause a retinal burn that may leave a permanent dark 1. Grounding the Equipment
area in the field of vision.
Arc welding equipment must be grounded according to
3. Protection of Nearby Personnel the National Electrical Code, and the work must be
Enclosed welding area. For production welding, a sepa- grounded according to ANSI Z49.1 “Safety In Welding
rate room or enclosed bay is best. In open areas, sur- And Cutting.”
round the operation with low-reflective, non-combusti- When installing, connect the frames of each unit such as
ble screens or panels. Allow for free air circulation, par- welding power source, control, work table, and water cir-
ticularly at floor level. culator to the building ground. Conductors must be ade-
OM-166 941 Page 4
quate to carry ground currents safely. Equipment made ject in contact with the electrode circuit unless
electrically HOT by stray current may shock, possibly the welding power source is off.
fatally. Do NOT GROUND to electrical conduit, or to a b. Equipment without output on/off control (no
pipe carrying ANY gas or flammable liquid such as oil or contactor)
fuel.
Welding power sources used with shielded
Three-phase connection. Check phase requirements of metal arc welding (SMAW) and similar proc-
equipment before installing. If only 3-phase power is esses may not be equipped with welding power
available, connect single-phase equipment to only two output on-off control devices. With such equip-
wires of the 3-phase line. Do NOT connect the equipment the electrode is electrically HOT when the
ment ground lead to the third (live) wire, or the equip- power switch is turned ON. Never touch the
ment will become electrically HOT-a dangerous condi- electrode unless the welding power source is
tion that can shock, possibly fatally. off.
Before welding, check ground for continuity. Be sure 7. Safety Devices
conductors are touching bare metal of equipment
Safety devices such as interlocks and circuit breakers
frames at connections.
should not be disconnected or shunted out.
If a line cord with a ground lead is provided with the Before installation, inspection, or service, of equipment,
equipment for connection to a switchbox, connect the shut OFF all power and remove line fuses (or lock or
ground lead to the grounded switchbox. If a three-prong red-tag switches) to prevent accidental turning ON of
plug is added for connection to a grounded mating re- power. Disconnect all cables from welding power
ceptacle, the ground lead must be connected to the source, and pull all 115 volts line-cord plugs.
ground prong only. If the line cord comes with a three-
prong plug, connect to a grounded mating receptacle. Do not open power circuit or change polarity while weld-
Never remove the ground prong from a plug, or use a ing. If, in an emergency, it must be disconnected, guard
plug with a broken off ground prong. against shock burns, or flash from switch arcing.
2. Electrode Holders Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
Fully insulated electrode holders should be used. Do
Power disconnect switch must be available near the
NOT use holders with protruding screws.
welding power source.
3. Connectors F. Protection For Wearers of Electronic Life Sup-
Fully insulated lock-type connectors should be used to port Devices (Pacemakers)
join welding cable lengths. Magnetic fields from high currents can affect pacemak-
4. Cables er operation. Persons wearing electronic life support
equipment (pacemaker) should consult with their doctor
Frequently inspect cables for wear, cracks and damage. before going near arc welding, gouging, or spot welding
IMMEDIATELY REPLACE those with excessively worn operations.
or damaged insulation to avoid possibly-lethal shock
from bared cable. Cables with damaged areas may be 1-4. STANDARDS BOOKLET INDEX
taped to give resistance equivalent to original cable.
For more information, refer to the following standards or
Keep cable dry, free of oil and grease, and protected their latest revisions and comply as applicable:
from hot metal and sparks. 1. ANSI Standard Z49.1, SAFETY IN WELDING
5. Terminals And Other Exposed Parts AND CUTTING obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami,
Terminals and other exposed parts of electrical units FL 33126.
should have insulating covers secured before opera-
tion. 2. NIOSH, SAFETY AND HEALTH IN ARC WELD-
ING AND GAS WELDING AND CUTTING ob-
6. Electrode tainable from the Superintendent of Documents,
a. Equipment with output on/off control (contac- U.S. Government Printing Office, Washington,
tor) D.C. 20402.
Welding power sources for use with the gas 3. OSHA, SAFETY AND HEALTH STANDARDS,
metal arc welding (GMAW), gas tungsten arc 29CFR 1910, obtainable from the Superinten-
welding (GTAW) and similar processes nor- dent of Documents, U.S. Government Printing
mally are equipped with devices that permit on- Office, Washington, D.C. 20402.
off control of the welding power output. When 4. ANSI Standard Z87.1, SAFE PRACTICES FOR
so equipped the electrode wire becomes elec- OCCUPATION AND EDUCATIONAL EYE AND
trically HOT when the power source switch is FACE PROTECTION obtainable from the Ameri-
ON and the welding gun switch is closed. Never can National Standards Institute, 1430 Broad-
touch the electrode wire or any conducting ob- way, New York, NY 10018.
OM-166 941 Page 5
5. ANSI Standard Z41.1, STANDARD FOR MEN’S 11. CGA Pamphlet P-1, SAFE HANDLING OF
SAFETY-TOE FOOTWEAR obtainable from the COMPRESSED GASES IN CYLINDERS obtain-
American National Standards Institute, 1430 able from the Compressed Gas Association,
Broadway, New York, NY 10018. 1235 Jefferson Davis Highway, Suite 501, Ar-
lington, VA 22202.
6. ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PROC- 12. CSA Standard W117.2, CODE FOR SAFETY IN
ESSES obtainable from the American National WELDING AND CUTTING obtainable from the
Standards Institute, 1430 Broadway, New York, Canadian Standards Association, Standards
NY 10018. Sales, 178 Rexdale Boulevard, Rexdale, On-
7. AWS Standard A6.0, WELDING AND CUTTING tario, Canada M9W 1R3.
CONTAINERS WHICH HAVE HELD COMBUS- 13. NWSA booklet, WELDING SAFETY BIBLIOG-
TIBLES obtainable from the American Welding RAPHY obtainable from the National Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126. Supply Association, 1900 Arch Street, Philadel-
8. NFPA Standard 51, OXYGEN-FUEL GAS SYS- phia, PA 19103.
TEMS FOR WELDING, CUTTING, AND ALLIED 14. American Welding Society Standard AWSF4.1,
PROCESSES obtainable from the National Fire RECOMMENDED SAFE PRACTICES FOR
Protection Association, Batterymarch Park, THE PREPARATION FOR WELDING AND
Quincy, MA 02269. CUTTING OF CONTAINERS AND PIPING
9. NFPA Standard 70, NATIONAL ELECTRICAL THAT HAVE HELD HAZARDOUS SUB-
CODE obtainable from the National Fire Protec- STANCES, obtainable from the American Weld-
tion Association, Batterymarch Park, Quincy, MA ing Society, 550 N.W. LeJeune Rd, Miami, FL
02269. 33126.
10. NFPA Standard 51B, CUTTING AND WELDING 15. ANSI Standard Z88.2, PRACTICE FOR RESPI-
PROCESSES obtainable from the National Fire RATORY PROTECTION, obtainable from the
Protection Association, Batterymarch Park, American National Standards Institute, 1430
Quincy, MA 02269. Broadway, New York, NY 10018.
SECTION 2 − SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1. GENERAL INFORMATION AND SAFETY 2-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
A. General
Information presented in this manual and on various la- The following safety alert symbol and signal words are
bels, tags, and plates on the unit pertains to equipment used throughout this manual to call attention to and
design, installation, operation, maintenance, and identify different levels of hazard and special instruc-
troubleshooting which should be read, understood, and tions.
followed for the safe and effective use of this equipment. This safety alert symbol is used with the signal
The nameplate of this unit uses international symbols words WARNING and CAUTION to call atten-
for labeling the front panel controls. The symbols also tion to the safety statements.
appear at the appropriate section in the text.
WARNING statements identify procedures or
B. Safety practices which must be followed to avoid seri-
The installation, operation, maintenance, and trouble- ous personal injury or loss of life.
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the CAUTION statements identify procedures or
safety of others. Therefore, this equipment is to be in- practices which must be followed to avoid minor
stalled, operated, and maintained only by qualified per- personal injury or damage to this equipment.
sons in accordance with this manual and all applicable
codes such as, but not limited to, those listed at the end IMPORTANT statements identify special instructions
of Section 1 − Safety Rules For Operation Of Arc Weld- necessary for the most efficient operation of this equip-
ing Power Source. ment.
OM-166 941 Page 6

Table 3-1. Welding Generator Specifications
Rated Output Maximum Maximum Single-Phase Weight

Welding Open-Circuit
At 100% Voltage Engine Speed Auxiliary Power
Duty Cycle Range (No Load) While Welding
(OCV) Net Ship
800 Amperes 100 to 800 95 Volts DC

3 kVA/kW 60 Hz 2150 lbs. 2280 lbs.
At 36 Volts DC Amps DC 80 Volts DC 1860 RPM 26 Amperes At 120 Volts (975 kg) (1034 kg)
Nominal
Conforms with NEMA EW1 (ANSI C87.1), “ELECTRIC ARC WELDING POWER SOURCES,” Class I (100).
47 in.
(1194 mm)
72 in.
(1829 mm)
32 in.
(813 mm)
21/32 in. (16.7 mm)
Dia. All Holes
Inches Millimeters
A 62-3/8 1584
B 50-1/2 1283
C 46-1/2 1181 A
D 36 914 B
E 28-3/16 716 C
F 13-3/4 349
E D
G 9-3/4 248
H 6-1/8 156
F
J 29-7/8 759 G
K 1-1/16 27
K J H
ST-147 323-B
Figure 3-1. Overall Dimensions And Mounting Hole Locations

OM-166 941 Page 7
3-1. DUTY CYCLE and Air Carbon Arc Cutting And Gouging (CAC-A) pro-
cesses.
The duty cycle of a welding generator is the percentage
of a ten minute period that a welding generator can be The unit is equipped with a four-cylinder, air-cooled,
operated at a given output without causing overheating Deutz diesel engine (F4L-912). The air compressor in
and damage to the unit. This welding generator is rated this unit is mounted on the front of the engine, and it op-
at 100 percent duty cycle when operated at 800 am- erates whenever the engine is running. The compressor
peres. This means that the welding generator can be op- delivers 12 cfm of air at a pressure of 100 psi (see Chart
erated at 800 amperes continuously without causing 3-2).
damage to the unit. In addition to welding and air compressor operation, this
unit can provide up to 3 kVA/kW of 120 volts (26 am-
3-2. VOLT-AMPERE CURVES (Chart 3-1) peres) ac electrical power for operating 50/60 Hz or 60
Hz auxiliary equipment while welding.
The volt-ampere curves show the voltage and amper-
age output capabilities of the welding generator at mini- This unit is specially prepared for operation in harsh and
mum and maximum of each coarse range. Curves of corrosive environments.
other settings fall between the curves shown. An optional Ether Starting Aid can be provided on the
welding generator and is covered within this Owner’s
Chart 3-1. Volt-Ampere Curves
Manual.
Chart 3-2. Air Output Curve
SB-168 387
3-3. DESCRIPTION
This unit is a constant current (CC) dc arc welding gen-
erator designed for use with the Shielded Metal Arc
Welding (SMAW), Flux Cored Arc Welding (FCAW), SB-143 883
SECTION 4 − INSTALLATION OR RELOCATION
IMPORTANT: Unless otherwise specified, all direc- CAUTION: RESTRICTED AIRFLOW causes
tions, such as left or right, are with respect to the opera- overheating and possible damage to inter-
tor facing the welding generator front panel. nal parts.
• Maintain at least 18 inches (457 mm) of unre-
4-1. LOCATION (Figure 3-1) stricted space on all sides of unit, and keep
underside free of obstructions.
A proper installation site should be selected for the weld-
ing generator if the unit is to provide dependable service
• Do not place any filtering device over the
intake air passages of this welding generator.
and remain relatively maintenance free.
Warranty is void if any type of filtering device is
WARNING: ENGINE EXHAUST GASES can used.
kill.
• Operate in open, well-ventilated areas or if
operated indoors, vent engine exhaust out- The service life and operating efficiency of this
side the building. unit are reduced when the unit is subjected to
• Keep engine exhaust vent outlet away from extreme levels of dust, dirt, moisture, corrosive
building air intakes. vapors, and extreme heat.
OM-166 941 Page 8
A. Lifting Of Equipment The mounting location should allow sufficient room to
remove the top cover and side panels for maintenance
WARNING: INCORRECT LIFTING will dam- and repair functions.
age internal parts; FALLING EQUIPMENT
can cause serious personal injury and Use a properly fitting cover (optional) over the welding
equipment damage. generator when not in operation to protect the unit from
• Use lifting eye to lift unit only, NOT gas cylin- the environment. Be sure unit is cool before installing
ders, trailer, or any other heavy options, ac- any cover.
cessories, or devices.
• Use equipment of adequate capacity to lift the C. Spark Arrestor Considerations
unit. WARNING: ENGINE EXHAUST SPARKS can
• Use lift forks at least 42 in. (1067 mm) long. cause fire.
• Lift only from engine-end (end opposite front
• Exhaust spark arrestor must be installed in
accordance with local, state, and federal
panel). regulations.
The engine exhaust system on this welding generator is
B. Trailer Mounting
not equipped with a spark arrestor. A spark arrestor,
CAUTION: UNCONTROLLED TILTING OF maintained in effective working order, is mandatory if
TRAILER can result in personal injury or this welding generator is to be operated in a National
equipment damage. Forest or on California Grasslands, brush, or forest cov-
• Distribute weight so that trailer tongue weight ered land (see Section 4442 of California Public Re-
is approximately 10% of gross trailer weight. sources Code). For other areas, check your state and
• Follow trailer manufacturer’s instructions local laws. If a spark arrestor (optional) is desired, con-
when mounting welding generator onto tact your dealer/distributor.
trailer.
4-2. EXHAUST EXTENSION INSTALLATION
OPERATION ON UNLEVEL SURFACE can
cause improper lubrication and result in WARNING: HOT ENGINE PARTS can cause
severe engine damage. severe burns.
• Operate unit in an approximately level posi- • If applicable, shut down engine and allow ex-
tion. haust system to cool before installing exhaust
• See Figure 4-1 for maximum allowable tilt for extension.
proper operation.
1. Install exhaust extension through top cover
• Check crankcase oil level with unit on a level opening, over muffler extension elbow. (Be sure
surface. to face end of extension away from air cleaner;
Exceeding these limits can cause severe engine see Figure 3-1).
damage and improper operation.
2. Secure exhaust extension to top cover of unit us-
ing supplied hardware.
Front
Panel 4-3. CONNECTING THE BATTERY
WARNING: BATTERY ACID can burn eyes
and skin and destroy clothing and other ma-
17.5 terial.
• Wear a face shield and proper protective
15 clothing when working with batteries.
Side View Of Unit
ABNORMAL VOLTAGE can cause damage
to engine electrical components.
Front
• Do not operate engine without the battery
Panel connected.
• Do not disconnect the battery while the en-
37.5 gine is running.
45 IMPORTANT: Be sure the Engine Control switch is in
End View Of Unit Ref. S-0024 the OFF position before connecting battery.
Figure 4-1. Allowable Tilt Angles For Welding This unit is equipped with a maintenance-free battery.
Generator Engine To place the unit in service, remove the left, rear side
panel, connect the negative (−) battery cable to the neg-
Holes are provided in the base for securing the unit in a ative battery terminal, and reinstall the side panel. No
permanent location or to a trailer or transport vehicle. other preparation should be required. If the battery does
Figure 3-1 gives overall dimensions and base mounting not supply enough power to crank the engine, charge
hole layout. the battery according to Section 8-6.
OM-166 941 Page 9
4-4. FUEL lower front panel of this unit (see Figure 4-2). If oil level is
below the lower pointer when engine is running, add oil
WARNING: REMOVE FUEL CAP SLOWLY;
FUEL SPRAY may cause injury; FUEL may according to the recommendations in the Engine Man-
be under pressure. ufacturer’s Manual (F4L-912 engine). The oil cap is lo-
• Rotate fuel cap slowly and wait until hissing cated under the access door on the top cover.
stops before removing cap. IMPORTANT: This engine is equipped with an Oil Pres-
ENGINE FUEL can cause fire or explosion. sure Shutdown gauge/switch and an Oil Temperature
• Stop engine before checking or adding fuel. Shutdown gauge/switch. If oil pressure becomes too
• Do not spill fuel; if spilled, wipe up. low or oil temperature rises to a level that may cause en-
gine damage, the respective gauge/switch shuts down
• Do not refuel if engine is hot or running. the engine. The shutdown oil pressure has been factory
• Do not refuel near sparks or open flame. set at 30 psi (207 kPa), and the shutdown oil tempera-
• Do not smoke while refueling. ture has been set at 265°F (130°C).
• Do not fill fuel tank to top; allow 1/2 in. (13 B. Wetstacking Considerations
mm) from fuel to tank top for expansion.
• Do not weld on fuel tank. Wetstacking is an accumulation of unburned fuel and oil
in the exhaust pipe. The engine may use oil and wet-
IMPORTANT: Fill fuel tank up to 1/2 in. (13 mm) from stacking may occur during the run-in period if the piston
top with fresh fuel before starting engine the first time. rings are not seated properly. If oil consumption and
Rust and corrosion preventative was added to inside of wetstacking occur during run-in period, see Section
fuel tank and engine at the factory and could cause 8-12.
rough engine running if not properly diluted with a full
tank of fresh fuel. 4-6. EQUIPMENT GROUNDING TERMINAL
The capacity of the fuel tank is 30 gallons U.S. Measure
(114 liters). See the Engine Manufacturer’s Manual for
fuel recommendations. Chart 4-1 illustrates typical fuel
consumption under specific load conditions. Fuel con- GROUND
sumption varies from one engine to another. Different This unit is equipped with a grounding terminal for
brands of fuel, operating conditions, condition of the en- grounding the generator case. The grounding terminal
gine, etc., also affect the fuel consumption level. is located on the lower front panel (see Figure 4-2).
Keep the fuel tank filled to ensure that the injector sys- Since the generator neutral is connected to the frame,
tem receives an adequate supply of fuel. The fuel cap is the equipment grounding terminal must be connected to
located on the lower front panel, behind the right access a proper earth ground. Additionally, comply with all na-
door (see Figure 4-2). If the fuel tank is allowed to empty, tional, regional, and local codes concerning portable
air will enter the system, causing starting problems. The generators for the specific application.
Engine Manufacturer’s Manual outlines procedures for For detailed grounding instructions consult your na-
air bleeding the fuel system. tional, regional, and local codes. If additional informa-
4-5. LUBRICATION (Figure 4-2) tion regarding your operating circumstances and/or
grounding requirements is needed, consult a qualified
A. Oil And Oil Level Indicator electrician or your dealer. After determining the extent to
The engine is shipped with its crankcase filled with SAE which any grounding requirements apply to your par-
20 break-in oil. An oil level indicator is provided on the ticular situation, follow them explicitly.
Chart 4-1. Fuel Consumption Curve
SB-168 472
OM-166 941 Page 10

4-7. WELD OUTPUT CONNECTIONS (Table 4-1 B. Weld Cable Preparation
And Figure 4-2)
1. Install electrode holder to cable following man-
RATED WELD OUTPUT ufacturer’s instructions. Always use an insulated
electrode holder to ensure operator safety.
2. Install correct size lugs onto ends of both cables
for connecting to work clamp, electrode holder or
To obtain full rated output from this unit, it is necessary to wire feeder, and weld output terminals.
select, prepare, and install proper weld cables. Failure 3. Install work clamp onto cable.
to comply in any of these areas may result in
unsatisfactory welding performance.
C. Weld Output Connections
A. Weld Cable Selection
Use the following guidelines to select weld cables: POSITIVE NEGATIVE
1. Use the shortest possible cables, and place
cables close together. Excessive cable lengths
may reduce output or cause unit overload due to
+ −
added resistance. WARNING: ELECTRIC SHOCK can kill.
2. Use weld cable with an insulation voltage rating • Do not touch live electrical parts.
equal to or greater than the maximum open-cir- • Stop engine, and disconnect negative (−) bat-
cuit voltage (ocv) of the welding generator (see tery cable before making any weld output
Table 3-1 for unit maximum ocv rating). connections.
MOVING PARTS can cause serious injury.
3. Select weld cable size according to maximum
weld output and total length of connecting cables • Keep away from moving parts such as fans,
in weld circuit. For example, if a 25 foot (7.5 m) belts, and rotors.
wire feeder or electrode holder cable is used with
1. Open and secure the lower front panel access
a 25 foot (7.5 m) work cable, select the cable size
door, and route weld cables through bracket on
recommended in Table 4-1 for 50 feet (15 m).
front upright to the weld output terminals (see
4. Do not use damaged or frayed cables. Figure 4-2).
Table 4-1. Weld Cable Size*
Total Cable (Copper) Length In Weld Circuit Not Exceeding

150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) Or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Welding 10 To 60% 60 Thru 100%
10 Thru 100% Duty Cycle
Amperes Duty Cycle Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0
700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0
800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0
900 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0
*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. S-0007-D
OM-166 941 Page 11

2. For Shielded Metal Arc Welding (SMAW) and Air 4-8. REMOTE CONTROL CONNECTIONS
Carbon Arc Cutting and Gouging (CAC-A) (Elec-
trode Positive/Reverse Polarity), connect weld A. Remote 9 Receptacle Information And
cables as follows: Connections (Figures 4-2 And 4-3)
a. Connect one end of work cable to NEGATIVE REMOTE 9

(−) weld output terminal.
FEEDER
b. Connect end of electrode holder cable to POSI-
AMPERAGE/
TIVE (+) weld output terminal. A/V VOLTAGE
IMPORTANT: For Electrode Negative/Straight Polarity
connections, reverse cable connections to weld output OUTPUT
terminals; electrode becomes negative. (CONTACTOR)
REMOTE 9 receptacle RC3, located under the lower
3. For Wire Feeding Processes (GMAW, FCAW, front panel access door (see Figure 4-2), is provided to
SAW) (Electrode Positive/Reverse Polarity), connect any of the following equipment to the welding
connect weld cables as follows: generator circuitry:
a. Connect one end of work cable to NEGATIVE a. Remote Contactor
(−) weld output terminal. b. Remote Amperage or Voltage control
b. Connect end of electrode holder cable to POSI- c. Wire feeder which provides contactor control to
TIVE (+) weld output terminal and remaining the welding generator.
end to terminal on the wire feeder drive housing d. Combination of the above.
(see wire feeder Owner’s Manual for location).
To Make connections, align keyway, insert plug, and ro-
4. Close and secure front panel access door. tate threaded collar fully clockwise.
Circuit Breaker CB3 Terminal

Strip 3T Circuit Breaker CB1
(see Section 9-3)
Remote 9
Receptacle
Equipment
Oil Level Grounding
Indicator Terminal
Strain Relief
Fuel Cap
POSITIVE (+) NEGATIVE (−)

Weld Output Weld Output
Terminals Terminals
Ref. ST-147 322-E
Figure 4-2. Lower Front Panel Components And Connections
OM-166 941 Page 12

If supplied remote control cord is not suitable for con-
necting to the REMOTE 9 receptacle RC3, proceed with
F
one of the following alternatives; G E
I
H D
1. Wire a plug or cord to interface with REMOTE 9
C
receptacle RC3 using socket information in Sec- A
B
tion C. Ref. S-0706
2. Wire remote control cord directly to terminal strip

within unit according to Section B. Figure 4-3. Front View Of Remote 9 Receptacle
With Socket Locations
B. REMOTE Terminal Strip 3T Information And
Connections (Figures 4-2 And 4-4)
Socket A/Terminal A:
WARNING: ELECTRIC SHOCK can kill; UN- Contact closure to Socket B/Terminal B
EXPECTED OUTPUT can cause serious in- completes the 115 volts ac contactor con-
jury. trol circuit; protected by circuit breaker
• Do not touch live electrical parts. CB3.
• Stop engine, and disconnect negative (−) Socket B/Terminal B:
battery cable from battery before making any
internal inspection or connections. Contactor closure to Socket A/Terminal A
• Do not connect to REMOTE 9 receptacle and completes the 115 volts ac contactor con-
trol circuit.
terminal strip at the same time.
Since the OUTPUT (CONTACTOR) can be en- Socket H/Terminal J:
ergized from either the receptacle or terminal Command reference; +10 volts dc.
strip, it is vital to use only one remote control
method. Socket F/Terminal G:
MOVING PARTS can cause serious injury. Control circuit common.
•Keep away from moving parts such as fans, Socket G/Terminal H:
belts, and rotors.
Input command signal from wiper of re-
mote control potentiometer; 0 volts equals
Terminal strip 3T, mounted on the lower front panel (see machine minimum; +10 volts equals ma-
Figure 4-2), is included in case the plug supplied on the chine maximum.
remote control cord is not suitable for connections to the
REMOTE 9 receptacle RC3. Socket C/Terminal C:
115 volts ac circuit common; also con-
To make connections, proceed as follows:
nected to welding power source chassis.
1. Remove existing plug from remote control cord. Socket D/Terminal D:
2. Open and secure lower front door. Up to 10 amperes of 115 volts ac, 60 Hz,
with respect to terminal C (circuit
3. Locate strain reliefs provided on lower front panel common).
(see Figure 4-2).
Terminals L and M of 3T:
4. Insert leads from cord through strain relief.
Terminals supply 30 amperes of 115 volts
5. For Remote Electrical Cutoff Switch, remove ac, 60 Hz, auxiliary power. Terminal L is
jumper link between terminals N and P. circuit common.
Terminals E/Terminal E or F:
6. Connect leads to terminal strip 3T using terminal
information provided in Section C. Weld Voltage Feedback. Polarity
determined by connection at terminal E (+)
7. Secure the cord in the strain relief. or F (−).
8. Close and secure door. Terminal N and P of 3T:
C. Socket/Terminal Information (Figure 4-4) Closed circuit between terminals N and P
is normal condition. Open circuit between
The following lists the functions of the sockets of RE- terminals N and P is Remote Emergency
MOTE 9 receptacle RC3 (see Figure 4-3), and the termi- Electrical Cutoff condition.
nals of strip 3T (see Figure 4-4). The following socket/
Terminal I/Terminal K:
terminal information is provided in case it is necessary to
wire the auxiliary equipment cord. Machine chassis (Equipment Ground).
OM-166 941 Page 13
4-9. AIR COMPRESSOR CONNECTIONS IMPORTANT: Before installing the ether cylinder, clean
nozzle on ether cylinder and fitting into which the ether
This unit delivers 12 cfm of air at a pressure of 100 psi cylinder is inserted. If dirt is present in either of these ar-
whenever the engine is running. A 1/2 in. NPT fitting for eas, the system may not work.
air compressor connections is provided on the top cover
of the unit. 1. Open and secure right rear side door.
To make connections to the air compressor, obtain and 2. If applicable, remove protective cap from ether
install a quick-connect connector onto the air compres- valve, or remove old ether cylinder from unit.
sor fitting.
3. Loosen cylinder clamp, install ether cylinder, and
4-10. ETHER STARTING AID (Optional) tighten clamp.
This unit is shipped without the ether cylinder. Before IMPORTANT: After installing or replacing ether cylin-
this device is operational, an ether cylinder must be ob- der, do not use or test ether start system for at least 10 to
tained and installed. To install the ether cylinder, pro- 15 minutes to allow particles in fuel to settle to prevent
ceed as follows: atomizer plugging.
WARNING: IMPROPER HANDLING OR EX- 4. Using a liquid soap and water solution, check all
POSURE TO ETHER can seriously harm ether start system connections for leaks. If a leak
your health.
exists, escaping gas will produce bubbles in the
• Follow the manufacturer’s safety instructions solution.
on the cylinder when handling ether compo-
nents. 5. Close and secure side door.
Ref. ST-164 613-A
Figure 4-4. Terminal Strip 3T Information
OM-166 941 Page 14

SECTION 5 − AUXILIARY POWER
A brief period (less than 5 seconds) of large current draw

is required for starting motor-driven equipment. This
generator can supply 25% of rated current output at the
POWER OUTPUT terminal strip for motor starting. Disconnect motor from
generator before starting engine. Use adequate size
cords so that voltage drop at the motor is not excessive.
WARNING: ELECTRIC SHOCK can kill; Voltage drops significantly when starting motor-driven
MOVING PARTS can cause serious injury; equipment.
IMPROPER AIR FLOW AND EXPOSURE TO Ground fault circuit interrupters (GFCI) may be re-
ENVIRONMENT can damage internal parts.
quired. Check local and state codes, and the latest issue
• Do not touch live electrical parts. of the National Electrical Code.
• Stop the engine and disconnect negative (−)
battery cable from battery before making in- 5-2. 120 VOLT TERMINALS (Chart 5-1, And
ternal inspection or reconnection. Figure 4-2)
• Ground generator as required by any applica- WARNING: ELECTRIC SHOCK can kill.
ble national, state, and local electrical codes.
• Do not touch live electrical parts.
The generator neutral is connected to the frame;
therefore, the equipment grounding terminal
• Stop engine, and disconnect negative (−)
must be connected to a proper earth ground. battery cable from battery before beginning
this installation.
• Do not connect to any electrical distribution MOVING PARTS can cause serious injury.
system normally supplied by utility power un-
less a proper transfer switch and grounding • Keep away from moving parts such as fans,
procedure are employed. belts, and rotors.
• Keep away from moving parts such as fans, HOT SURFACES can cause severe burns.
belts, and rotors. • Wear protective gloves and clothing when
• Keep all covers and panels in place while op- working near a hot engine.
erating. • Allow components to cool completely be-
fore touching.
Warranty is void if unit is operated with any por-
tion of the outer enclosure removed. IMPORTANT: All directions, such as left or right, are
ELECTRIC SPARKS can cause fire. with respect to the operator facing the welding generator
• Disconnect weld cables when using auxiliary front panel. Retain all hardware removed during this
power. procedure for reinstallation unless specifically told
otherwise.
The weld output terminals are electrically ener-
gized when the engine is running and the con-
tactor (if applicable) is energized. Chart 5-1. AC Power Curve For 120 Volt Terminals
• Watch for fire.
• Have a fire extinguisher nearby, and know
how to use it.
LOW VOLTAGE AND FREQUENCY can dam-
age electrical equipment.
• Turn off or unplug all electrical equipment
connected to auxiliary power before starting
or stopping the engine.
When starting or stopping, the engine has low
speed which causes low voltage and frequency.
5-1. GENERAL
Calculate load requirements before connecting equip-
ment to the auxiliary power terminals on terminal strip
3T. For best performance (voltage and frequency regu-
lation), limit connected load to approximately 90% of
generator capability. SB-109 365-B
OM-166 941 Page 15

A. Auxiliary Equipment Connections To Terminal 3. Locate three strain reliefs on lower front panel.
Strip 3T (Figure 4-2)
4. Insert leads from cord(s) through a strain relief.
WARNING: Read and follow safety infor-
mation at beginning of entire Section 5-2 5. Connect leads to terminal strip 3T using terminal
before proceeding. information provided in Figure 4-4.
Terminal strip 3T is provided to directly wire the auxiliary 6. Secure the cord(s) in the strain relief(s).
power cord(s) into the unit. To make connections, pro- 7. Close and secure door.
ceed as follows:
B. Protection
1. Remove plug from auxiliary equipment cord(s), if
Circuit breaker CB1 protects the 120 volts ac auxiliary
applicable.
power terminals from overload. See Section 9-3 for CB1
2. Open and secure lower front door. location and resetting procedure.
SECTION 6 − OPERATOR CONTROLS
Amperage & Service Engine Remote Amperage & Output

Voltage Adjustment Air Cleaner Voltage Switch (Contactor)
Control Light Switch
Check Alternator
Light
Engine Control
Switch
Voltmeter
Ammeter Fuel Gauge
Battery Ampere
Gauge
Ampere
Ranges
Switch
Engine Hours Oil Temperature Oil Pressure

Meter Gauge/Switch Gauge/Switch Ref. ST-147 322-E
Figure 8-1. Operator Controls
6-1. AMPERE RANGES SWITCH (Figure 6-1) The AMPERAGE & VOLTAGE ADJUSTMENT control
The Ampere Ranges switch provides two coarse am- adjusts welding amperage within range selected by Am-
perage ranges. When in LOW OUTPUT, amperage pere Ranges switch.The scale surrounding the control
range is 100-350 amperes. When in HIGH OUTPUT, is calibrated in percent and does not indicate an actual
amperage range is 300-800 amperes. amperage or voltage value.
CAUTION: ARCING can damage switch IMPORTANT: The AMPERAGE & VOLTAGE AD-
contacts. JUSTMENT control may be adjusted while welding.
• Do not change the position of the Ampere 6-3. ENGINE CONTROL SWITCH (Figure 6-1)
Ranges switch while welding or under load.
Arcing causes the contacts to become pitted
and eventually inoperative.
6-2. AMPERAGE & VOLTAGE ADJUSTMENT

CONTROL (Figure 6-1)
A/V
AMPERAGE AND VOLTAGE The Engine Control switch has three positions: START,
ADJUSTMENT RUN, and OFF.
OM-166 941 Page 16
A. START Position If remote amperage or voltage is not desired, place the
AMPERAGE & VOLTAGE switch in the PANEL posi-
tion. Only the AMPERAGE & VOLTAGE ADJUST-
MENT control will adjust output.
6-5. OUTPUT(CONTACTOR) SWITCH (Figure

Rotating the switch to the START position starts the en- 6-1)
gine. Release the switch as soon as the engine starts,
and the switch automatically returns to the RUN posi-
tion. ON
B. RUN Position
REMOTE
RUN
OUTPUT
When the Engine Control switch is in the RUN position, (CONTACTOR)
engine speed remains at governed weld/power speed
(1860 rpm). WARNING: ELECTRIC SHOCK can kill.
C. OFF Position • Do not touch live electrical parts.
• Do not touch the output terminals when the
contactor is energized.
• Do not touch welding wire or electrode and
work clamp at same time.
When the OUTPUT/CONTACTOR switch is in
Rotating the Engine Control switch to the OFF position the ON position, open-circuit voltage is present
disconnects battery voltage, thereby shutting down the at the weld output terminals for as long as the
engine. engine is running.
6-4. REMOTE AMPERAGE & VOLTAGE CON- If the OUTPUT(CONTACTOR) switch is in the ON posi-
TROL SWITCH (Figure 6-1) tion, open-circuit voltage will be present at the output
terminals whenever the engine is running.
If remote contactor control by means of a wire feeder or
PANEL remote device is desired, make connections to the RE-
MOTE 9 receptacle or terminal strip 3T according to
Section 4-8, and place the OUTPUT(CONTACTOR)
REMOTE switch in the REMOTE position. Open-circuit voltage is
present at the weld output terminals whenever the gun
A/V switch or remote device is closed.
WARNING: ELECTRIC SHOCK can kill. 6-6. SERVICE ENGINE AIR CLEANER LIGHT
• Do not touch live electrical parts. (Figure 6-1)
• Do not touch the output terminals when the This unit is equipped with an engine air cleaner. When
contactor is energized the SERVICE ENGINE AIR CLEANER light PL1 comes
• Do not touch welding wire or electrode and on, the air cleaner requires servicing (see Section 8-2).
work clamp at same time.
6-7. CHECK ALTERNATOR (Figure 6-1)
If remote amperage or voltage control is desired, make
connections to the REMOTE 9 receptacle terminal strip The CHECK ALTERNATOR light PL3 comes on if the al-
according to Section 4-8, and place the AMPERAGE & ternator requires servicing. If the light comes on, check
VOLTAGE switch in the REMOTE position. When a Re- for loose or broken engine belt.
mote Amperage or Voltage Control is being used, the re-
mote control functions as a fine amperage or voltage ad- 6-8. HOUR METER (Figure 6-1)
justment for the AMPERAGE & VOLTAGE ADJUST-
MENT control on the welding generator. For example, if
the AMPERAGE & VOLTAGE ADJUSTMENT control
on the welding generator is set at midrange, the Remote
Amperage or Voltage Control will provide (from mini-
mum to maximum adjustment) fine amperage or voltage
adjustment of one half of the welding generator output This unit is equipped with an hour meter. The meter, la-
for the range selected. For complete remote control of beled ENGINE HOURS, registers the total hours of en-
the output, rotate the AMPERAGE & VOLTAGE AD- gine operation. This information is useful for routine
JUSTMENT control to the maximum position. maintenance on the engine.
OM-166 941 Page 17
6-9. FUEL GAUGE (Figure 6-1) 6-13. BATTERY GAUGE (Figure 6-1)
FUEL BATTERY
The FUEL Gauge indicates the level of fuel remaining in
The BATTERY voltmeter registers the alternator-
the fuel tank. The unit is equipped with a 30 gallon (114
supplied output voltage to the battery. The meter should
L) fuel tank.
always register 12-15 volts dc while the engine is run-
ning. If the voltage is outside this range, stop the engine,
6-10. MAGNETIC SHUTDOWN SWITCH and determine the cause. Do not operate the engine un-
til the trouble has been corrected.
An internal switch automatically shuts down the engine
if oil pressure drops to an unsafe level or oil temperature
becomes too high.
6-14. METERS (Figure 6-1)
The switch assembly is located directly behind the up-
The meters are provided to monitor the welding opera-
per front panel access door, in the upper left corner. The
tion; however, they are not intended for exact amperage
switch is protected by a fuse located on the bottom of the
or voltage measurements. These meters are internally
switch assembly. Should this fuse open, the engine
connected to the output circuit.
would not start. See Section 9-3 for fuse replacement
procedure. The voltmeter indicates the voltage at the weld termi-
nals, but not necessarily the actual voltage at the weld-
6-11. OIL TEMPERATURE GAUGE/SWITCH (Fig- ing arc (due to cable resistance, poor connections, etc.).
ure 6-1) The ammeter indicates the amperage output of the unit.
6-15. BROKEN COOLING BELT SHUTDOWN

SWITCH
An internal switch automatically shuts down the engine
if the cooling belt breaks. The cooling belt is located on
the rear of the engine. If the engine shuts down, check
The OIL TEMPERATURE gauge/switch registers the for broken cooling belt.
temperature of the oil in the lubricating system. If the oil
temperature rises to a level that may cause engine dam-
age (factory set at 265°F, 130°C), switch closes and 6-16. ETHER STARTING AID (Optional)
magnetic shutdown switch stops the engine (see Sec-
tion 6-10). The cold weather starting components provide a means
of applying a premeasured portion of ether into the man-
ifold. The amount of ether supplied should be sufficient
6-12. OIL PRESSURE GAUGE/SWITCH (Figure to permit easy engine starting under cold weather condi-
6-1) tions.
Depressing ETHER STARTING AID switch for one sec-
ond while cranking the engine will provide the proper
amount of ether to the manifold. This control will function
only while cranking the engine.
The OIL PRESSURE gauge/switch registers the lubri- CAUTION: ETHER INJECTION WHILE EN-
cating system pressure in pounds per square inch (psi). GINE IS RUNNING can cause engine dam-
age.
The pressure registered by the gauge should remain
constant for a given engine speed. Should the pressure • Do not actuate ETHER STARTING AID while
fluctuate or drop, stop the engine, and do not operate engine is running.
until the trouble has been corrected. If the oil pressure
drops to a level that may cause engine damage, switch
closes and magnetic shutdown switch stops the engine IMPORTANT: Ether is sprayed into the engine when
(see Section 6-10). The shutdown oil pressure is factory this switch is released. Depressing the switch does not
set at 30 psi (207 kPa). Normal operating pressure is ap- spray the ether into the engine but rather fills the valve
proximately 50 psi (345 kPa). chamber.
OM-166 941 Page 18
SECTION 7 − SEQUENCE OF OPERATION
WARNING: ELECTRIC SHOCK can kill; 7-1. SHIELDED METAL ARC WELDING (SMAW)
MOVING PARTS can cause serious injury;
IMPROPER AIR FLOW AND EXPOSURE TO WARNING: Read and follow safety informa-
ENVIRONMENT can damage internal parts. tion at beginning of entire Sections 5 and 7
before proceeding.
• Stop the engine and disconnect negative (−) 1. Install and connect unit according to Section 4.
battery cable from battery before inspecting
or servicing. 2. Wear dry insulating gloves and clothing.
• Keep away from moving parts such as fans, 3. Connect work clamp to clean, bare metal at
belts, and rotors. workpiece.
• Keep all covers and panels in place while op- 4. Select proper electrode.
erating.
Warranty is void if the welding generator is oper- 5. Set Ampere Ranges switch and rotate AMPER-
ated with any portion of the outer enclosure re- AGE & VOLTAGE ADJUSTMENT control to the
moved. desired position (see Sections 6-1 and 6-2).
ARC RAYS can burn eyes and skin; NOISE 6. If remote amperage control is not used, place
can damage hearing. AMPERAGE & VOLTAGE switch in the PANEL
• Wear correct eye, ear, and body protection.
position. If remote amperage control is to be
used, place AMPERAGE & VOLTAGE switch in
FUMES AND GASES can seriously harm the REMOTE position.
your health.
7. If remote contactor control is not used, place
• Ventilate to keep from breathing fumes and OUTPUT(CONTACTOR) switch in the ON posi-
gases. tion. If remote contactor control is to be used,
• If ventilation is inadequate, use approved place OUTPUT(CONTACTOR) switch in the RE-
breathing device. MOTE position.
• Use in open, well ventilated areas or vent ex- 8. Start engine as instructed in Section 7-6.
haust out of doors.
9. Connect desired auxiliary equipment to the 120
HOT METAL, SPATTER, SLAG, and EX-
HAUST can cause fire and burns. volts ac terminals according to Section 5.
• Watch for fire.

10. Place Engine Control switch in the RUN position.
• Have a fire extinguisher nearby, and know 11. Energize auxiliary equipment, if applicable.
how to use it. 12. Wear welding helmet with proper filter lens ac-
• Allow work and equipment to cool before han- cording to ANSI Z49.1.
dling.
13. Insert electrode into electrode holder.
ENGINE FUEL can cause fire or explosion.
14. Begin welding.
• Stop engine before checking or adding fuel.
• Do not spill fuel; if spilled, wipe up. 7-2. GAS METAL ARC (GMAW) AND FLUX
• Do not refuel if engine is hot or running.
CORED ARC WELDING (FCAW)
• Do not refuel near sparks or open flame. WARNING: Read and follow safety informa-
• Do not smoke while refueling. tion at beginning of entire Sections 5 and 7
• Do not fill tank to top; allow room for expan-
before proceeding.
sion.
1. Install and connect unit according to Section 4.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation. 2. Install and connect wire feeder to the terminal
strip according to wire feeder Owner’s Manual
• Wearers should consult with their doctor be- and Section 4-8.
fore going near arc welding, gouging, or spot
welding operations. 3. Wear dry insulating gloves and clothing.
See Section 1-Safety Rules For Operation Of 4. Connect work clamp to clean, bare metal at
Arc Welding Power Source for basic welding workpiece.
safety information.
5. Set Ampere Ranges switch and rotate AMPER-
AGE & VOLTAGE ADJUSTMENT control to the
desired position (see Section 6-1 and 6-2).
OM-166 941 Page 19
6. If remote amperage or voltage control is not Table 7-1. Suggested Electrode Diameter For
used, place AMPERAGE & VOLTAGE switch in Amperage Range (CAC-A Only)
the PANEL position. If remote amperage or volt-
age control is to be used, place AMPERAGE & Electrode Diameter Amperage Range
VOLTAGE switch in the REMOTE position.
Inches Millimeters Minimum Maximum
7. If remote contactor control is not used, place 1/8 3.2 30 60
OUTPUT(CONTACTOR) switch in the ON posi-
tion. If remote contactor control is to be used, 5/32 4.0 90 150
place OUTPUT(CONTACTOR) switch in the RE- 3/16 4.8 200 250
MOTE position.
1/4 6.4 300 400
8. Turn on shielding gas supply, if applicable.
5/16 7.9 350 450
9. Start engine as instructed in Section 7-6. 3/8 9.5 450 600
10. Connect desired auxiliary equipment to the 120 1/2 12.7 800 1000
volts ac terminals according to Section 5.
5/8 15.9 1000 1250
11. Place Engine Control switch in the RUN position. 3/4 19.0 1250 1600
12. Energize auxiliary equipment, if applicable. 1 25.4 1600 2200
13. Wear welding helmet with proper filter lens ac-

cording to ANSI Z49.1. 7-4. AUXILIARY POWER OPERATION
14. Begin welding. WARNING: Read and follow safety informa-
tion at beginning of entire Sections 5 and 7
before proceeding.
7-3. AIR CARBON ARC CUTTING AND GOUGING 1. Install and connect unit according to Section 4.
(CAC-A) (Table 7-1)
2. Install and connect auxiliary power equipment
cord(s) to 120 volts auxiliary power terminals ac-
WARNING: Read and follow safety informa-
tion at beginning of entire Sections 5 and 7 cording to Section 5-2.
before proceeding. 3. Start engine as instructed in Section 7-6.
4. Place Engine Control switch in the RUN position.
1. Install and connect unit according to Section 4. 5. Energize auxiliary equipment, if applicable. Auxil-
iary power may be obtained whenever engine is
2. Wear dry insulating gloves and clothing.
running.
3. Connect work clamp to clean, bare metal at work-
piece. 7-5. AIR COMPRESSOR OPERATION (Tables 7-2
And 7-3)
4. Place AMPERAGE & VOLTAGE switch in the
PANEL position. 1. Install and connect unit according to Section 4.
2. Install a quick-connect connector onto the air
5. Place OUTPUT(CONTACTOR) switch in the ON
compressor fitting in top cover of unit.
position.
3. Start engine as instructed in Section 7-6.
6. Set Ampere Ranges switch and rotate AMPER- 4. Begin operation.
AGE & VOLTAGE ADJUSTMENT control to the
desired position (see Sections 6-1 and 6-2).
7-6. STARTING THE ENGINE
7. Start engine as instructed in Section 7-6.
IMPORTANT: Read entire engine Owner’s Manual
8. Connect desired auxiliary equipment to the 120 (Deutz F4L-912 engine) before operating engine.
volts ac terminals according to Section 5.
1. Engine Prestart Checks
9. Place Engine Control switch in the RUN position. a. Oil Level
10. Energize auxiliary equipment, if applicable. Check engine oil level. If oil level is low, fill to top
mark on dipstick (see engine Owner’s Manual
11. Wear welding helmet with proper filter lens ac- for oil selection specifications and Section 4-5).
cording to ANSI Z49.1.
If oil consumption and wetstacking occur during
12. Begin welding. run-in period, see Section 8-12.
OM-166 941 Page 20
b. Fuel Level release ETHER STARTING AID switch after one
second.
WARNING: REMOVE FUEL CAP SLOWLY;
FUEL SPRAY may cause injury; FUEL may CAUTION: REENGAGING STARTER MO-
be under pressure. TOR while flywheel is rotating or EXCEED-
• Rotate fuel cap slowly and wait until hissing ING RATED CRANKING TIME can damage
starting components.
stops before removing cap.
• Do not reengage starter motor until starter
Check fuel level. If necessary, fill tank with pinion and flywheel have stopped rotating.
fresh, clean fuel (see engine Owner’s Manual • Do not exceed maximum cranking time of 20
for fuel specifications). seconds.
Allow two minutes cooling time before attempt-
c. Cooling System ing to restart engine.
Check the air cooling system by inspecting the
3. As soon as engine starts, release Engine Control
air intake and exhaust openings for blockage switch, and allow the engine to warm up for ap-
and blower impeller for obstruction and free proximately three minutes with no weld or power
movement. Check the blower/alternator belt for
load applied.
proper tension (see the engine Owner’s Man-
ual), and ensure that all sheet metal cowlings,
shrouds, and panels are properly in place and 7-7. STOPPING THE ENGINE
secure. 1. Stop all operations, and turn off or disconnect any
d. Air Cleaner auxiliary equipment.
Check air cleaner service indicator daily (see WARNING: HIGH CONCENTRATION OF
Section 6-6). SHIELDING GAS can harm health or kill.
• Shut off gas supply when not in use.
2. Rotate Engine Control switch to the START posi-
tion, and if applicable, depress ETHER START- 2. Rotate Engine Control switch to the OFF posi-
ING AID switch, if applicable, at the same time — tion.
Table 7-2. Flow Of Free Air (CFM) Through Orifices Of Various Diameters
Gauge Pressure In Orifice Diameter And Free Air Flow (CFM)

Receiver (lbs.)
1/64” 1/32” 3/64” 1/16” 3/32” 1/8” 3/16” 1/4”
1 0.027 0.107 0.242 0.430 0.97 1.72 3.86 6.85
2 0.038 0.153 0.342 0.607 1.36 2.43 5.42 9.74
3 0.046 0.188 0.471 0.750 1.68 2.98 6.71 11.9
5 0.059 0.242 0.545 0.965 2.18 3.86 8.71 15.4
10 0.084 0.342 0.77 1.36 3.08 5.45 12.3 21.8
15 0.103 0.418 0.94 1.67 3.75 6.65 15.0 26.7

20 0.119 0.485 1.07 1.93 4.25 7.7 17.1 30.8
25 0.133 0.54 1.21 2.16 4.75 8.6 19.4 34.5
30 0.156 0.632 1.40 2.52 5.6 10.0 22.5 40.0
35 0.173 0.71 1.56 2.80 6.2 11.2 25.0 44.7
40 0.19 0.77 1.71 3.07 6.8 12.3 27.3 49.1

45 0.208 0.843 1.9 3.36 7.6 13.4 30.3 53.8
50 0.225 9.14 2.05 3.64 8.2 14.5 32.8 58.2
60 0.26 1.05 2.35 4.2 9.4 16.8 37.5 67.0
70 0.295 1.19 2.68 4.76 10.7 19.0 43.0 76.0
80 0.33 1.33 2.97 5.32 11.9 21.2 47.5 85.0

90 0.364 1.47 3.28 5.87 13.1 23.5 52.5 94.0
100 0.40 1.61 3.66 6.45 14.5 25.8 58.3 103.0
110 0.43 1.76 3.95 7.00 15.7 28.0 63.0 112.0
120 0.47 1.90 4.27 7.58 17.0 30.2 68.0 121.0
130 0.50 2.04 4.57 8.13 18.2 32.4 73.0 130.0

140 0.54 2.17 4.87 8.68 19.5 34.5 78.0 138.0
150 0.57 2.33 5.2 9.20 20.7 36.7 83.0 147.0
175 0.66 2.65 5.94 10.6 23.8 42.1 95.0 169.0
200 0.76 3.07 6.90 12.2 27.5 48.7 110.0 195.0
OM-166 941 Page 21

Table 7-3. Approximate Air Consumption (Cubic Feet) Required To Operate Various Pneumatic
Equipment At Pressure Range 70-90 P.S.I.G.
MISCELLANEOUS Percent Use Factor And MISCELLANEOUS Percent Use Factor And
PORTABLE Compressed Air Consumption (CF) PORTABLE Compressed Air Consumption (CF)
TOOLS 9 sec 15 sec 21 sec 1 min TOOLS 9 sec 15 sec 21 sec 1 min
Drill, 1/18” to 3/8” 3.75 6.25 8.75 25 Burring Tool, Large 3.6 6.0 8.4 24
Drill, 3/8” to 5/16” 5.25 8.75 12.25 35 Rammers, Small 3.9 3.25 9.1 13
Screwdriver,
#2 to #6 Screw 1.8 3.0 4.2 12 Rammers, Medium 5.1 8.5 11.9 34
Screwdriver,
#6 to 5/16” Screw 3.6 6.0 8.4 24 Rammers, Large 6.0 10.0 14.0 40
Tapper, to 3/8” 3.0 5.0 7.0 20 Backfill Tamper 3.75 6.25 8.75 25
Nutsetters, to 3/8” 3.6 6.0 8.4 24 Compression Riveter 0.2 cu. ft. per cycle
Nutsetters, to 3/4” 4.5 7.5 10.5 30 Air Motor,

1 Horsepower 3.75 6.3 8.75 25
Impact Wrench, 1/4” 2.25 3.75 5.3 15 Air Motor,

2 Horsepower 7.5 12.5 17.5 50
Impact Wrench, 3/8” 3.0 5.0 7.0 20 Air Motor,

3 Horsepower 11.25 18.75 26.3 75
Impact Wrench, 5/8” 4.5 7.5 10.5 30
Air Motor Hoist
Impact Wrench, 3/4” 5.25 8.75 12.25 35 1000# 1 cu. ft. per foot of lift
Impact Wrench, 1” 6.75 11.25 15.75 45 Air Motor Hoist,

2000# 1 cu. ft. per foot of lift
Impact Wrench, 1-1/4” 8.25 13.75 19.2 55
Paint Spray Gun
Die Grinder, Small 2.25 3.75 5.3 15 (Production) 3.0 5.00 7.00 20
Die Grinder, Medium 3.6 6.0 8.4 24 HAMMERS
Horizontal Grinder, 2” 3.0 5.0 7.0 20 Scaling Hammer 1.3 3.0 4.2 12
Horizontal Grinder, 4” 9.0 15.0 21.0 60 Chipping Hammer 4.5 7.5 10.5 30
Horizontal Grinder, 6” 9.0 15.0 21.0 60 Riveting Hammer,

Light 2.25 3.75 5.25 15
Horizontal Grinder, 8” 12.0 20.0 28.0 80 Riveting Hammer,

Heavy 4.5 7.5 10.5 30
Vertical Grinders and
Sanders, 5” Pad 5.25 8.75 12.25 35 SAWS
Vertical Grinders and Circular, 8” 6.75 11.25 15.75 45

Sanders, 7” Pad 9.0 15.0 21.0 60
Circular, 12” 9.75 16.25 23.8 65
Vertical Grinders and
Sanders, 9” Pad 10.5 17.5 24.5 70 Chain, Lightweight 4.20 7.0 9.8 28
Burring Toll, Small 2.25 3.75 5.3 15 Chain, Heavy Duty 13.1 21.8 30.5 87
Always check with tool manufacturers for actual air consumption of tools being used. The above is based on averages and should not be
considered accurate for any particular make of tool.
Above tools are rated based upon typical “on-load” performance characteristics.
For other values, adjust the C.F. air consumption on a proportional basis.
The cubic feet (C.F.) air consumption for 1 minute may also be expressed as air consumption in cubic feet per minute (C.F.M.)
OM-166 941 Page 22

SECTION 8 − MAINTENANCE
8-1. ROUTINE MAINTENANCE (Table 8-1) C. Oil, Filter, And Drain

IMPORTANT: Every six months inspect the labels on WARNING: Read and follow safety informa-
this unit for legibility. All precautionary labels must be tion at beginning of entire Section 8-1 before
maintained in a clearly readable state and replaced proceeding.
when necessary. See the Parts List for part numbers of
The engine is equipped with a full-flow oil filter. Change
precautionary labels.
the oil and filter according to instructions on unit mainte-
WARNING: ELECTRIC SHOCK can kill. nance label and in engine Owner’s Manual (Deutz
• Do not touch live electrical parts. F4L-912 engine). Use correct type and grade of oil as
• Stop engine, and disconnect negative (−) listed in instructions for expected temperature range be-
fore next oil and filter change.
battery cable from battery before inspecting,
maintaining, or servicing. This unit is equipped with an oil drain hose secured in a
MOVING PARTS can cause serious injury. clamp behind the rear panel. A valve is provided in the
• Keep away from moving parts such as fans, hose inside the right side base rail. To drain oil from en-
belts, and rotors. gine, remove drain hose from clamp and open valve.
HOT ENGINE PARTS can cause severe Close valve and reinstall hose into clamp before adding
burns. new oil.
• Wear protective gloves and clothing when IMPORTANT: This engine is equipped with an Oil Pres-
working on a hot engine. sure Shutdown gauge/switch and an Oil Temperature
BATTERY ACID can burn eyes, skin, destroy Shutdown gauge/switch. If oil pressure becomes too
clothing, and damage other material. low or oil temperature rises to a level that may cause en-
• Wear correct eye and body protection. gine damage, the respective gauge/switch shuts down
the unit. The shutdown oil pressure has been factory set
Maintenance to be performed only by qualified
persons. at 30 psi (207 kPa), and the shutdown oil temperature
has been set at 265° F (130° C).
A. Cables And Wiring
D. Cleaning And Inspecting
tion at beginning of entire Section 8-1 before WARNING: Read and follow safety informa-
proceeding. tion at beginning of entire Section 8-1 before
proceeding.
Check interconnecting wiring and connections for
tightness and flaws. Be sure that the weld output cable When performing routine oil changes at intervals
connections are clean and tight. Check the insulation for specified on the unit maintenance label, clean and
breaks or other signs of damage. Repair or replace inspect the unit as follows:
cables or wiring as necessary. 1. Keep the inside of the welding generator clean by
B. Battery blowing out the unit with clean, dry compressed
air.
tion at beginning of entire Section 8-1 before 2. Wipe oil and fuel spills from engine immediately
proceeding. to avoid accumulation of dust.
Inspect the battery for loose connections, damaged 3. Check for fluid leaks indicating loose oil or fuel
cables, corrosion, cracked case or cover, loose connections. Tighten loose connections, and
holddowns, and loose or deformed terminal posts. clean oil or fuel spills off engine.
Clean and tighten connections, replace cables, or IMPORTANT: See the engine Owner’s Manual (Deutz
replace battery if necessary. F4L-912 engine) for complete engine care.
Table 8-1. Maintenance Schedule
Frequency* Maintenance
Every day. Check fuel and oil levels (see Sections 4-4, 4-5, and 8-1C, and engine Owner’s Manual,
Deutz F4L-912 engine).
Every 100 to 150 hours. Change oil and filter (see engine Owner’s Manual, Deutz F4L-912 engine).
Check cables, wiring (see Section 8-1A), and battery (see Section 8-1B).
Units in heavy service environments: Check labels; clean and inspect unit (see Section 8-1).
Change fuel/water separator (see Section 8-3).
Every 250 hours. Check and clean spark arrestor muffler (see Section 8-11).
Every 1000 hours. Replace fuel filter (see Section 8-4).Check brushes and slip rings (see Section 8-9).
Check all labels (see IMPORTANT block, Section 8-1). Clean and inspect unit (see Section 8-1D).
*Frequency of service is based on unit operated 40 hours per week. Increase frequency of maintenance if usage exceeds 40 hours per week.
OM-166 941 Page 23
OM-166 941 Page 24
Air Filter Service . . . . . . 50 hours or less − see Owner’s Manual
DEUTZ F4L912 DIESEL ENGINE Air Filter Element . . . . . MILLER 020 319, AC 302C, Donaldson P10-1222,
Fleetguard AF437K, Fram CAK 253, Purolator AF-2030K
See Engine Manual for complete engine care. Engine Cooling
Give Engine Specification and Serial Number when ordering parts.
Avoid recirculation of air from hot air exit to blower intake.
Blower Belt . . . . . . . . . . . Deutz 223-5531, MILLER 064 690
°C °F Alternator Belt . . . . . . . . . Deutz 223-5179, MILLER 066 213
+40 Compressor Belts (2) . . . Deutz 116-1683
Check
daily. +30 Battery . . . . . . . . BCI Group 31
+
30
+20 Cranking Performance at 0°F (-18°C) . . . . . . 815 Amps
Recommended Oil . . . . . API Service Classification CD/CE
+60
Oil And Filter Change . . . dirty conditions . . . 100 hours or less +10 Valve Clearance −Cold
normal conditions . 125−150 hours +40 Engine RPM − No Load
20W-20
Intake . . . . . 0.006 in (0.15 mm)
Oil Filter . . . . . . . . . . . . . . MILLER 064 677, Deutz 117-4418, 0 +30 Weld/Power . . . . 1850
Exhaust . . . 0.006 in (0.15 mm)
Fleetguard LF4056, Fram PH2842, -10
10W
Hastings P352 or FP352
Oil Capacity . . . . . . . . . . . 11.5 qt (11 L) or -20 -10
12 qt (11.4 L) with filter change Injectors . . . . . . . . . . . . . . MILLER 064 684, Deutz 223-3085
Nozzle . . . . . . . . . . . . . . . MILLER 064 685, Deutz 223-3086
Have only trained technician maintain injection pump and injectors. AIR, WATER, or
GASOLINE will harm the injection system. If tank is run out of fuel or fuel filter is
Fuel Capacity . . . . . . . . . 30 gal (113.6 L) changed, bleeding of air is required.
Figure 8-1. Engine Maintenance Label

Fuel Grade . . . . . . . . . . . 1-D or 2-D Cetane No. 45 min. Do NOT
Primary Fuel Filter/ use ether.
Water Seperator . . . . . . . MILLER 062 342, Fleetguard FF194, Fram P1107
Secondary Fuel Filter . . . Deutz 117-4423, Fleetguard FF5018, Fram P4102 Spark Arrestor Inspection And Service . . . . . . . . . . 250 operating hours −
Diesel MILLER 064 686 see Owner’s Manual
Fill filter with clean fuel before installing − read instructions on filter. Optional S-146 389-B
8-2. AIR CLEANER SERVICE (Table 8-2) The air cleaner on this unit is equipped with precleaners.
CAUTION: DIRTY AIR can damage engine. Remove the precleaner cover and empty the dust re-
• Do not operate engine with dirty air cleaner ceptacle when dirt accumulates up to the indicator
marks on the side of the precleaner.
element in place.
• Do not operate engine without air cleaner ele-
ment in place. IMPORTANT: A dirty air cleaner element is usually ac-
companied by a loss of power and excessive smoke in
The air cleaner is one of the most important parts of the
the engine exhaust.
engine from the standpoint of engine life. If dirty air gets
into the engine, it can cause major engine damage
within a few operating hours. The air cleaner must be When it becomes necessary to service the air cleaner in
serviced when the SERVICE ENGINE AIR CLEANER the field, follow the steps in Table 8-2. Keep a spare ele-
Indicator light PL1 comes on. If PL1 comes on, empty ment on hand for replacement. New elements are avail-
dust cap, and inspect air cleaner and element. able from your welding equipment distributor.
Table 8-2. Air Cleaner Service
1. Stop engine. 5. Wipe out element chamber 7. Reinstall element.

Follow with clean, damp cloth.
2. Wipe off cover before 8. Replace cover.
These opening air cleaner. 6. Inspect new element and all
Easy gaskets for shipping damage before use.
Steps: 3. Remove cover.
4. Remove element.
1. Don’t attempt to service air 3. Don’t leave open air cleaner exposed 5. For Donaclone air cleaners ,
cleaner with engine running. to blowing dust while you clean element. don’t blow out Donaclone tube
Replace cover. section without element, cover
Important 2. Don’t blow out the inside of and inner cover (if any)
the air cleaner with compressed 4. If air cleaner is horizontally mounted, correctly installed or you will
air. be sure that dust cup is positioned so blow dust into the engine.
arrows point up.
Clean element by one of the re-use. However, washing does (When cleaning Cyclopac
How To following methods: a better job and must be used when elements, do not remove
Clean exhaust soot has lodged in fine pores plastic fin assembly − back-
Elements Compressed Air or Washing. of the filter media. Use Donaldson D-1400
detergent which contains a special
flowing with compressed air or
washing will remove dust from
For Compressed air is recommended additive for removing soot and carbon. beneath the fin assembly).
Re-Use when element will be re-used
immediately because a washed Replace element after 6 cleanings or
element must be dried before annually, whichever occurs first.
Compressed Air Washing Inspection
Direct air through element in 1. Soak element 15 minutes or more Place bright light inside
the direction opposite to normal in Donaldson D-1400 and water solution. element and rotate element
air flow through the element. See carton for full instructions. slowly. If any rupture, holes
Move nozzle up and down while or damaged gaskets are
rotating element. Keep nozzle 2. Rinse until water is clear (Maximum discovered − replace.
at least one inch from pleated water pressure 40 P.S.I.)
paper. Maximum air pressure −
100 P.S.I. 3. Air-dry or use warm flowing air, max.
160 F. Do not use compressed air or
light bulbs. S-0091/4-89
OM-166 941 Page 25

8-3. FUEL/WATER SEPARATOR AND SLUDGE Oil Fill Cap
DRAIN PLUG
WARNING: ENGINE FUEL can cause fire or

explosion.
• Do not drain fuel tank while engine is running. Fuel Filter
• Do not smoke while handling fuel.

• Do not allow fuel to drain onto the engine or Engine Speed
Adjustment
other components. Screw
• Do not spill fuel; if spilled, wipe up.
• Have a fire extinguisher nearby, and know
how to use it.
A. Fuel/Water Separator
The fuel/water separator, located on the right base rail
near the engine, is provided to drain off water from the
fuel system. Before starting the engine for the first time
each day, open the fuel drain plug on the bottom of the
separator, and drain the water into a metal container.
Ref. ST-147 321-A
Close the drain plug at the first signs of fuel. The fuel/ Figure 8-2. Right Side And Rear View Of Engine
water separator should be changed every 125 hours of
operation or every four months, whichever occurs first.
8-5. BATTERY REPLACEMENT PROCEDURE
B. Sludge Drain Plug
WARNING: SPARKS OR FLAMES can cause
A sludge drain plug, located on the lower right front cor- BATTERY GASES to explode; BATTERY
ner of the unit, is provided to drain off sediment from the ACID can burn eyes and skin.
fuel tank. Once a week, drain the sludge into a metal • Stop engine before disconnecting or
container. If the fuel is extremely dirty, drain the sludge connecting battery cables.
daily. • Keep sparks, flames, cigarettes, and other
ignition sources away from batteries.
• Do not allow tools to cause sparks when
working on a battery.
8-4. FUEL FILTER (Figure 8-2)
• Always wear a face shield and proper
protective gloves and clothing when working
WARNING: ENGINE FUEL can cause fire or on a battery.
explosion.
• Stop engine before working on fuel system. Use the following procedure to prevent sparks when
removing or installing a battery:
• Do not spill fuel; if spilled wipe up.
1. Be sure engine is fully stopped, and Engine
• Do not service fuel filter if engine is hot or run- Control switch is in the OFF position.
ning.
• Do not service fuel filter near sparks or open 2. Locate battery in unit.
flame. 3. Open door or remove panels as necessary.
• Do not smoke while servicing fuel filter. 4. Disconnect negative (−) battery cable first and
• Have a fire extinguisher nearby, and know positive (+) cable last.
how to use it.
5. Remove holddown device.
6. Remove battery.
This welding generator is equipped with a cartridge-type
fuel filter located above the oil filter on the right side of 7. Install new (or charged) battery.
the unit. The fuel filter should be replaced after 1000 8. Reinstall and secure holddown device.
hours of operation, or more often depending on the qual-
9. Connect positive (+) cable first and negative (−)
ity of fuel used and how dusty and dirty the location is in
cable last.
which the engine is being used. To replace the fuel filter,
refer to the Engine Manufacturer’s Manual. 10. Securely reinstall or close doors or panels.
OM-166 941 Page 26

8-6. MAINTENANCE-FREE BATTERY CHARG- 3. If the battery does not have removable vent caps,
ING check the condition of the battery as follows:
a. Check the stabilized open−circuit voltage of the
WARNING: CHARGING A FROZEN BAT- battery. For a 12 volt battery, any reading below
TERY can cause the battery to explode and
result in serious personal injury or damage 12.4 volts indicates the battery needs charging.
to equipment. Disconnect both battery cables from the bat-
• Allow battery to warm up to 60° F (16°C) be- tery, and allow battery voltage to stabilize for
several hours.
fore charging if battery is frozen.
BATTERY ACID can burn eyes and skin and b. If the stabilized open−circuit voltage is below
destroy clothing and other materials; BAT- 12.4 volts, charge the battery following the bat-
TERY GASES can explode and shatter battery charger manufacturer’s instructions.
tery.
4. Remove damp cloth from battery.
• Wear a face shield, proper protective cloth-
ing, and remove all metal jewelry. 5. Reinstall battery in unit.
• Do not spill or splash battery fluid. 6. Replace battery holddown, and tighten securely.
• Do not apply pressure to walls of filled bat- Do not overtighten.
tery—use battery carrier or place hands on 7. Connect positive (+) battery cable to positive (+)
opposite corners when lifting battery. battery terminal.
• Keep sparks, flames, cigarettes, and other ig- 8. Connect negative (−) battery cable to negative
nition sources away from batteries.
• Use enough ventilation to keep battery gases (−) battery terminal.
from building up during and for several hours 8-7. GOVERNOR
after battery charging.
• Do not touch or move connections on battery The governor has been set at the factory and should not
require further adjustment.
while battery charger is on.
• Turn battery charger off before making con- 8-8. ENGINE SPEED ADJUSTMENTS (Figure 8-2)
nections to battery.
WARNING: ELECTRIC SHOCK can kill.
• Do not lean over battery when charging. • Do not touch live electrical parts.
• Be sure battery charger connections to bat- • Stop engine, and disconnect negative (−)
tery are clean and tight.
battery cable from battery before inspecting,
• Keep vent caps in place and cover top of bat- maintaining, or servicing.
tery with damp cloth. MOVING PARTS can cause serious injury.
• Be sure battery charger output matches bat- • Keep away from moving parts such as fans,
tery voltage. belts, and rotors.
• Turn the battery charger off before discon- HOT ENGINE PARTS can cause severe
necting the charger from the battery. burns.
• Wear protective gloves and clothing when
1. Remove battery from unit, and place on a level working on a hot engine.
worktable or other suitable surface. Maintenance to be performed only by qualified
persons.
2. If battery has removable vent caps, check the
condition of the electrolyte as follows: The engine speeds have been factory adjusted and
should not require frequent readjustment. After tuning
a. Check electrolyte temperature in one of the
center cells with a battery thermometer. For the engine, check the speeds with a tachometer. With
each 10°F (6°C) increment above 80°F (27°C), no load applied, the weld/power speed should be 1860
rpm. If necessary, adjust the speeds as follows:
a correction factor of 0.004 specific gravity
must be added to the specific gravity reading 1. Open and secure right rear side door.
taken in Step 2b. For each 10°F (6°C) incre- 2. Loosen nut on end of engine speed adjusting
ment below 80°F (27°C), 0.004 must be sub- screw (see Figure 8-2).
tracted from the reading taken in Step 2b.
3. Start the engine as instructed in Section 7-6.
b. Check the specific gravity of each cell with a hy-
drometer. (Draw in and expel the electrolyte two 4. Adjust the weld/power speed as follows:
or three times from the first cell to be tested to IMPORTANT: All directions, such as clockwise and
adjust the temperature of the hydrometer to counterclockwise, are with respect to the operator fac-
that of the electrolyte.) ing the rear panel of the unit.
c. If a corrected specific gravity reading of 1.225 at a. To increase weld/power speed, rotate the en-
80°F (27°C) is not obtained, replace the vent gine speed adjustment screw clockwise.
caps and recharge the battery following the bat- b. To decrease weld/power speed, rotate the en-
tery charger manufacturer’s instructions. gine adjustment screw counterclockwise.
OM-166 941 Page 27
5. When the weld/power speed reaches 1860 rpm, No indicator is provided to show the amount of ether left
prevent the adjustment screw from turning, and in the cylinder; therefore, it is recommended that a spare
tighten the securing nut. cylinder be kept on hand. Generally, the ether cylinder is
empty if the engine fails to start in cold weather while uti-
6. Stop engine.
lizing the cold weather starting system.
7. Close and secure side door.
WARNING: IMPROPER HANDLING OR EX-
POSURE TO ETHER can seriously harm
8-9. BRUSHES AND SLIP RINGS (Figure 8-3) your health.
• Follow the manufacturer’s safety instructions
WARNING: ELECTRIC SHOCK can kill on the cylinder when handling ether compo-
• Do not touch live electrical parts. nents.
• Stop engine, and disconnect negative (−) bat-
tery cable from battery before inspecting, The cylinder can be weighed to determine the amount
maintaining, or servicing. of ether inside. The cylinder weighs 33 ounces (936 gr)
MOVING PARTS can cause serious injury. when full, and it weighs 15 ounces (425 gr) when empty.
• Keep away from moving parts such as fans, To replace the ether cylinder, see Section 4-10.
belts, and rotors.
IMPORTANT: Before installing the ether cylinder, clean
HOT ENGINE PARTS can cause severe nozzle on ether cylinder and fitting into which the ether
burns.
cylinder is inserted. If dirt is present in either of these ar-
• Wear protective gloves and clothing when eas, the system may not work.
working on a hot engine.
Brush life is very good under most operating conditions. IMPORTANT: After installing or replacing ether cylin-
The brushes and slip rings should be inspected every der, do not use or test ether start system for at least 10 to
six months or whenever excitation voltage is lost. Be 15 minutes to allow particles in fuel to settle to prevent
sure that slip rings are clean and brushes are free to atomizer plugging.
move. If the welding generator has been operating un-
der extremely dusty or dirty conditions, increase the fre-
quency of inspection. 8-11. SPARK ARRESTOR
Under normal use, the slip rings will discolor to a dark
brown. If a buildup of brush material is noted, it may be WARNING: ELECTRIC SHOCK can kill.
necessary to clean the slip rings. Clean rings with a • Do not touch live electrical parts.
number 220 or finer sandpaper, and polish rings with • Stop engine and disconnect negative (−)
crocus cloth. Never use emery cloth because part of the battery cable from battery before beginning
emery will embed itself into the rings and, in turn, de- this installation.
stroy the carbon brushes.
MOVING PARTS can cause severe injury.
Replace the brushes if they become chipped or broken • Keep away from moving parts such as fans,
or if less than 1/2 in. (12.7 mm) of brush material is left. belts, and rotors.
ENGINE EXHAUST SPARKS can cause fire.
1/2 in. (12.7 mm) • Exhaust spark arrestor must be installed in
Minimum accordance with local, state, and federal
regulations.
• Stop engine before cleaning spark arrestor.
• Clean spark arrestor in a noncombustible
S-0234
environment.
HOT PARTS can cause severe burns.
Figure 8-3. Brush Replacement
• The exhaust system must be cold when
servicing the spark arrestor.
8-10. ETHER STARTING AID (Optional)
Internal combustion engines operating in a highly com-
CAUTION: ETHER INJECTION WHILE bustible environment are a common fire hazard. Glow-
ENGINE IS RUNNING can cause engine ing carbon particles blown out with the exhaust can re-
damage.
tain sufficient heat to ignite materials. While no practical
• Do not actuate ETHER STARTING AID while spark arresting device will stop all sparks, this device will
engine is running. minimize fire hazards by removing and trapping most
solid particles provided that is is properly maintained.
The ether used in the cold weather starting aid system is
contained in a replaceable cylinder located behind the Inspect and service spark arrestor every 250 operation
right rear side door on the center portion of the frame. hours.
OM-166 941 Page 28
Removal of the device from the exhaust system is not occur during the run-in period if the engine is left at idle
necessary for servicing. Proceed as follows to service rpm too long, or the welding generator is not heavily
spark arrestor: loaded.
1. Stop the engine, and allow the exhaust system to If wetstacking occurs, complete one of the following pro-
cool. cedures to dry the engine (see engine Owner’s Manual,
F4L-912 diesel engine). A resistance load is required to
2. Remove the cleanout plug from the bottom of the fully load the generator during the run-in procedure. A
spark arrestor. If a crust has formed over the load bank or resistance grid may provide a constant load
hole, break it loose with a screwdriver or similar for run-in, however, a load bank is preferred. If a load
tool. bank is available, proceed with the run-in procedure pro-
3. Start the engine, and run it at idle rpm to blow col- vided in Subsection A. If a resistance grid is being used,
lected particles out the cleanout hole. If particles proceed to Subsection B.
are slow to discharge, momentarily cover the end A. Run-In Procedure Using Load Bank (Diagram
of the exhaust stack. 8-1)
4. Stop the engine, and allow the exhaust system to
WARNING: Read and follow safety infor-
cool. mation at beginning of entire Section 8-12
before proceeding.
5. Replace and secure the cleanout plug.
1. Stop engine.
8-12. RUN-IN PROCEDURE
IMPORTANT: Weld cables supplied with load bank may
WARNING: ELECTRIC SHOCK can kill. be inadequate for run-in procedure. Use weld cables of
• Do not touch live electrical parts. proper size with appropriate connectors to connect load
bank to generator (see load bank Owner’s Manual).
• Stop engine before inspecting, connecting,
or servicing. 2. Connect cables from load bank to generator weld
• Do not leave live unit unattended when output terminals observing correct polarity (see
engine is running. Diagram 8-1).
• Keep all panels, covers, and guards 3. Place all load switches in the OFF position.
securely in place while engine is running.
MOVING PARTS can cause severe injury. IMPORTANT: If load bank requires 115 volts ac, it may
• Keep away from moving parts such as fans, be connected to the welding generator auxiliary power
belts, and rotors. terminal strip, if applicable.
HOT ENGINE PARTS can cause severe
burns. 4. Place welding generator AMPERAGE & VOLT-
• Wear protective gloves and clothing when AGE ADJUSTMENT control in the minimum po-
working on hot engine parts or components. sition.
5. Start engine as instructed in Section 7-6, and al-
CAUTION: LOW OIL LEVEL can damage low engine to warm up for approximately three
engine; ENGINE MAY USE OIL AND WETS- minutes.
TACKING may occur during run-in period.
• Check oil level several times a day during 6. Adjust load bank switches and generator controls
run-in period, and add oil if required. to provide a load equal to rated generator output.
• See engine Owner’s Manual (Deutz For example, if rated generator output is 350 am-
F4L-912 diesel engine) for run-in informa- peres, 40 volts at 100% duty cycle, adjust
tion.
switches until values indicated by load meters
• Do not idle engine longer than necessary equal rated generator output.
during run-in period.
• Piston rings seat faster if engine runs at 7. Allow engine to run under load for at least one
weld/power rpm, and the welding generator hour. Check engine and load bank meters after
is kept loaded during the run-in period. the first five minutes and every 15 minutes there-
after to be sure equipment is operating properly.
The run-in procedure for diesel engines is different than 8. After running engine under load for at least one
those associated with gasoline engines. Diesel engines hour, remove load by shutting down load bank.
must be run at near-rated load during the run-in period to
ensure proper seating of piston rings and to prevent 9. Allow engine to idle for approximately three min-
wetstacking. Wetstacking is an accumulation of un- utes to permit internal engine temperatures to
burned fuel and oil in the exhaust pipe. Wetstacking can equalize.
OM-166 941 Page 29
Welding
Generator
Load Bank
Positive (+) Negative (−)

Weld Output + − Weld Output
Terminal Terminal − + Voltmeter
And
Ammeter
Weld
Cables
S-0456
Diagram 8-1. Load Bank Connections
10. Stop engine, and disconnect load bank cables. are not provided, connect voltmeter and clamp-
on dc ammeter as shown in Diagram 8-2.
11. Allow exhaust system to cool.
9. Connect remaining ends of weld cables to gener-
12. Inspect inside of exhaust pipe. If pipe is dry, the
ator weld output terminals (polarity is not impor-
run-in procedure is complete. If pipe is coated
tant).
with a wet, black, tar-like substance, repeat run-
in procedure. 10. Start engine as instructed in Section 7-6, and al-
B. Run-In Procedure Using Resistance Grid (Dia- low engine to warm up for approximately three
gram 8-2) minutes.
WARNING: Read and follow safety infor- CAUTION: ARCING can damage switch
mation at beginning of entire Section 8-12 contacts.
before proceeding. • Do not change the position of the grid
switches while engine is running.
1. Stop engine. Arcing causes the contacts to become pitted
and eventually inoperative.
2. Obtain resistance grid adequately sized for rated
output of welding generator.
11. Check meters. Adjust load with generator con-
3. Obtain two weld cables of proper size to connect
trols or, if necessary, by changing positions of grid
resistance grid to generator (see Section 4-7). switches until values indicated by meters equal
4. If a voltmeter and ammeter are not provided on rated generator output.
the welding generator, obtain a voltmeter and
12. Allow engine to run under load for at least one
clamp-on dc ammeter.
hour. Check engine and meters after the first five
5. Place welding generator AMPERAGE & VOLT- minutes and every 15 minutes thereafter to be
AGE ADJUSTMENT control in the minimum posure equipment is operating properly
sition.
13. After running engine under load for at least one
6. Adjust grid switches and generator controls to hour, remove load by shutting down resistance
provide a load approximately equal to rated gen- grid.
erator output.
14. Allow engine to idle for approximately three min-
For example, if rated generator output is 350 am- utes to permit internal engine temperatures to
peres, 40 volts at 100% duty cycle, adjust equalize.
switches until values indicated by meters equals
rated generator output. 15. Stop engine, and disconnect weld cables.
7. Connect one weld cable to grid input receptacle 16. Allow exhaust system to cool.
and remaining weld cable to grid output recep-
17. Inspect inside of exhaust pipe. If pipe is dry, the
tacle (see Diagram 8-2).
run-in procedure is complete. If pipe is coated
8. If a voltmeter and ammeter are provided on the with a wet, black, tar-like substance, repeat run-
welding generator, proceed to Step 9. If meters in procedure.
OM-166 941 Page 30
Welding
Generator
Voltmeter And Resistance Grid
Ammeter
(If so equipped)
Input And Output

Receptacles
Weld Output
Terminals
(Polarity Not
Important)
Weld
Cables ♦ Clamp-On
V DC Ammeter
♦ Voltmeter
A
♦ Required if welding generator is not equipped with meters.

S-0457
Diagram 8-2. Resistance Grid Connections
9-1. GENERAL • Wear correct eye and body protection, and

remove all metal jewelry.
It is assumed that proper installation has been made,
according to Section 4 of this manual, the operator is fa- • Keep jumper cables clear of moving parts.
miliar with the function of controls, the welding generator • Ensure that both batteries are of the same
was functioning properly, and the trouble is not related to voltage.
the welding process.
• Do not jump start a trailer mounted welding
generator with the towing vehicle battery un-
9-2. BOOSTER BATTERY JUMP STARTING less the trailer is completely disconnected
from the towing vehicle.
If it is necessary to jump start this unit, use the following • Do not jump start a vehicle mounted welding
safety precautions and the step-by-step procedures in generator from the vehicle battery.
order of appearance.
• If booster battery is installed in vehicle, do not
allow vehicle to make contact with welding
generator case or frame.
WARNING: BATTERY GASES OR A DAM-
AGED BATTERY can explode thereby shat- • Do not jump start by applying power to weld
tering the battery; BATTERY ACID can burn output receptacles or terminals.
eyes, skin, destroy clothing, and damage
other material; MOVING PARTS AND IM-
• Do not allow jumper cables to contact any
PROPER CONNECTIONS can cause serious other metal while attaching or removing ca-
bles.
personal injury and damage equipment.
• Keep sparks, flames, cigarettes, and other ig- 1. Use properly insulated jumper cables of ade-
nition sources away from battery.
quate size.
• Ensure that all personnel are a safe distance
2. Connect ends of one cable to positive (+) termi-
from batteries and clear of moving parts while
starting. nals of each battery.
• Do not jump start a frozen or completely dis- 3. Connect one end of other cable to negative (−)
charged battery. terminal of booster battery.
• Do not jump start a battery which has loose 4. Connect remaining end of cable to welding gen-
erator engine block at least 18 inches (457 mm)
terminals or one having evidence of damage
such as a cracked case or cover. from battery (do not connect to welding generator
case, frame, or equipment grounding terminal as
• Be sure that vent caps are tight and level on damage to equipment can result).
both batteries and cover both batteries with a
damp cloth. 5. Wait at least one minute after connecting cables
before starting engine.
OM-166 941 Page 31
6. Start engine following procedures outlined in If CB3 opens, 115 volts ac output to socket/terminal D of
Section 7 (Sequence of Operation) of this man- REMOTE 9 receptacle RC3 and terminal strip 3T stops,
ual. If the unit does not start after cranking for and the remote amperage/voltage control will not
twenty seconds, stop the jump starting proce- function.
dure. More than twenty seconds seldom starts
the engine unless some mechanical adjustment C. Replacement Of Low Oil Pressure/High Oil
is made. Temperature Shutdown System Fuse F
7. Remove jumper cable from engine block.
8. Remove other end of same cable from booster tion at beginning of Section 9-3 before pro-
battery negative (−) terminal. ceeding.
9. Remove other jumper cable from booster battery
positive (+) terminal. 1. Remove securing screws, and open upper front
10. Remove remaining end of cable from welding access door.
generator battery positive (+) terminal. 2. Locate shutdown switch MS1 on left, rear side of
11. Discard damp cloths. front access door.
3. Locate fuse F on bottom of shutdown switch
9-3. OVERLOAD PROTECTION (Figure 4-2) MS1.
WARNING: ELECTRIC SHOCK can kill. 4. Remove and check fuse, and replace if neces-
• Do not touch live electrical parts. sary.
• Stop engine, and disconnect negative (−) bat- 5. Close and secure front access door.
tery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious personal 9-4. CIRCUIT BOARD HANDLING PRECAU-
injury. TIONS
• Keep away from moving parts such as fans, WARNING: ELECTRIC SHOCK can kill
belts, and rotors.
burns. • Stop engine, and disconnect negative (−) bat-
tery cable from battery before inspecting,
• Wear protective gloves and clothing when maintaining, or servicing.
INCORRECT FUSE can damage unit. burns.
• Be sure replacement fuse is same size, type, • Wear protective gloves and clothing when
and rating. working on a hot engine.
A. Circuit Breaker CB1 (Figure 4-2)
CAUTION: ELECTROSTATIC DISCHARGE
WARNING: Read and follow safety informa- (ESD) can damage circuit board compo-
tion at beginning of Section 9-3 before pro- nents.
ceeding. • Put on properly grounded wrist strap BE-
FORE handling circuit boards.
Circuit breaker CB1 protects the 120 volts ac auxiliary • Transport all static−sensitive components in
power terminals on terminal strip 3T from overload. CB1 proper static-shielding carriers or packages.
is located behind the lower front door. When CB1 opens, • Perform work only at a static−safe work area.
the ON/OFF switch goes to the OFF position, and 3T will
INCORRECT INSTALLATION or misaligned
not operate. If CB1 opens, locate and correct the prob- plugs can damage circuit board.
lem, and place the circuit breaker switch in the ON posi-
tion.
• Be sure that plugs are properly installed and
aligned before closing access door.
B. Circuit Breaker CB3 (Figure 4-2) EXCESSIVE PRESSURE can break circuit
board.
WARNING: Read and follow safety informa- • Use only minimal pressure and gentle move-
tion at beginning of Section 9-3 before pro- ment when disconnecting or connecting
ceeding. board plugs and removing or installing board.
Circuit breaker CB3 protects the unit wiring from over- If any circuit board is not working, follow the precautions
load and damage. CB3 is located behind the lower front above, and contact the nearest Factory Authorized Ser-
door. vice Station/Service Distributor.
OM-166 941 Page 32
9-5. TROUBLESHOOTING (Tables 9-1 Thru 9-4) The following tables are designed to diagnose and pro-
vide remedies for some of the troubles that may develop
WARNING: ELECTRIC SHOCK can kill.
in this welding generator.
Use these tables in conjunction with the circuit diagram
• Stop engine, and disconnect the negative (−) while performing troubleshooting procedure. If the
battery cable before inspecting, maintaining, trouble is not remedied after performing these proce-
or servicing.
dures, contact the nearest Factory Authorized Service
MOVING PARTS can cause serious injury. Station/Service Distributor. In all cases of equipment
• Keep away from moving parts such as fans, malfunction, strictly follow the manufacturer’s proce-
and rotors. dures and instructions.
burns.
• Wear protective gloves and clothing when
Troubleshooting to be performed only by quali-
fied persons.
Table 9-1. Weld/Power Troubleshooting
TROUBLE PROBABLE CAUSE REMEDY

No weld output. Amperage Ranges switch S9 Place S9 in LOW OUTPUT or HIGH OUTPUT
between positions. position (see Section 6-1).
OUTPUT (CONTACTOR) Place S5 in ON position, or install Remote Con-
switch S5 in REMOTE position tactor Control device.
and Remote Contactor device
not connected.
Incorrect or poor connection to Check and secure connections (see Section
REMOTE 9 receptacle or termi- 4-8).
nal strip 3T.
Circuit breaker CB3 open Reset CB3 (see Section 9-3).
(GMAW only).
Poor contact between slip rings Clean slip rings (see Section 8-9).
and brushes.
Replace brushes according to Section 8-9.
Field Current Regulator board See Section 9-4, and contact nearest Factory
PC1. Authorized Service Station/Service Distributor.
Erratic weld output. Loose or dirty connections. Check connections both inside and outside the
unit.
Connection at work. Check connection. Be sure connection is clean
and tight.
Damp electrode. Use dry, properly stored electrode.
Electrode polarity. See Section 4-7C.
High welding output voltage. High engine speed. Check and adjust engine speed according to
Section 8-8.
Wire feeder inoperative. Circuit breaker CB3. Reset CB3 according to Section 9-3.
OM-166 941 Page 33
Table 9-2. Auxiliary Power Troubleshooting
AUXILIARY POWER
PROBABLE CAUSE REMEDY
TROUBLE
No 120 volt output at 3T termi- Circuit breaker CB1 open. Reset CB1 (see Section 9-3).
nals L and M.
Poor contact between slip Clean slip rings (see Section 8-9).
rings and brushes.
Replace brushes according to Section 8-9.
High auxiliary power output High engine speed. Check and adjust engine speed according to
voltage. Section 8-8. (Maximum voltages should not
exceed 132 volts for single-phase power.)
Table 9-3. Engine Troubleshooting
TROUBLE PROBABLE CAUSE REMEDY

Engine does not start. Out of fuel. Fill fuel tank, and air vent fuel system (see En-
gine Manufacturer’s Manual.)
Battery problem. Check engine battery charging system accord-
ing to engine service manual (not supplied with
engine).
Inspect electrical system (see Section 8-1). If
trouble is isolated to battery, replace it.
Jump start the engine using approved safety
practices and booster battery (see Section
9-2).
Engine Control switch S1. Check S1, and replace if necessary.
Oil Pressure gauge/switch or See Sections 6-10 thru 6-11; see Engine Man-
Oil Temperature gauge/switch ufacturer’s Manual (F4L-912 engine).
activated, or other engine
trouble.
MS1 fuse F. Check and replace F, if necessary (see Sec-
tion 9-3).
Engine suddenly shuts down. Broken cooling belt. Check and replace belt (see Section 6-15).
High oil temperature. Check engine oil level and add oil if necessary;
check for cooling air flow obstructions.
Low oil pressure. Check engine oil level, and add oil if necessary
(see Section 4-5).
MS1 fuse F. Check and replace F if necessary (see Section
9-3).
Table 9-4. Air Compressor Troubleshooting
AIR COMPRESSOR
CAUSE REMEDY
TROUBLE
Air compressor fails to build Engine air compressor. Service air compressor. Contact nearest Au-
pressure or builds pressure thorized Service Station/Service Distributor.
slowly.
Pneumatic tools freeze up. Moisture in compressed air. Induce an antifreeze solution into the air sup-
ply. Contact nearest Authorized Service Sta-
tion/Service Distributor.
OM-166 941 Page 34

NOTES
OM-166 941 Page 35

SECTION 10 − ELECTRICAL DIAGRAMS
Diagram 10-1. Circuit Diagram For Welding Generator

OM-166 941 Page 36
SC-168 908-B
OM-166 941 Page 37

13
12 14
15 27
11
16 26
3 28
10 17
2 25
9 18
OM-166 941 Page 38

1 7
8 19 24
7
6 20 23
5
4 22 29
4 21
30
15
79 60
59
55
61 56 31
78 58 57 54
62
53
17 52 32
76 77
63 1 33
51
64 50 36 37
Fig 35
11-2 65 Fig 11-4
Figure 11-1A. Main Assembly

34
49
66 Fig 11-3
75 48 38
1
47
39
46
42 40
69 41
74 70 45 42
68
73 67 36 37 44 43
72 71
ST-800 491-B (1 of 2)
Item Dia. Part
Figure 11-1A. Main Assembly
... 1 . . . . . . . . . . . . . . . . . . . 134 834 .. HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . 4ft
... 2 . . . . . . . . . . . . . . . . . . . 131 123 .. SHIELD, heat upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . . . . . . 146 240 .. BRACKET, heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . . . . . . . . . 1063920009309 .. HOSE, air 43.000 3/4 swivel both ends . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . 0302390009309 .. FITTING, stl flrd conn fem 1/2tbg x 1/2NPT . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . 1261610009309 .. FITTING, pipe brs adapter 1/2NPT x M22 x 1.5 . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . 1448660009309 .. SEAL, ring copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 8 . . . . . . . . . . . . 1448670009309 .. VALVE, control air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . 1448320009309 .. FITTING, pipe brs adapter 1/2fem NPT x M22 x 1.5 . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . . . . . . 602 904 .. FITTING, pipe stl elb st .500NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . . . . . . . 010 917 .. HANGER, minerallic No. 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 12 . . . . . . . . . . . . 1224390009309 .. AIR LINE, tank to exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . . . . . . 138 098 .. HOSE, sst brd 20.750 lg 3/4NPT M ftg x 3/4NPT M INV
(same as Item 5 Fig 11-1B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . Shunt . . . . . . . . . 072 426 . . SHUNT, meter 50MV 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . . . . . 025 248 . . STAND-OFF, insul .250-20 x 1.250 lg . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 16 . . . . . . . . . . . 14172390009309 . . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . PLG7,12 . . . . . . . . 047 636 . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . 079 535 . . . . CONNECTOR, circ pin push-in 14-18ga Amp 66359-6 . . . . . . . . 14
. . . 18 . . . . . . . . . . . . . . . . . . . 143 922 . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3 . . . . . . . . 2
. . . 19 . . . . T2 . . . . 1479850009309 . . TRANSFORMER, control (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC8 . . . . . . . . . . 167 640 . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 113 633 . . . . . . CONNECTOR, rect pin 20-14ga Amp 350218-1 . . . . . . . . . . . . 4
. . . . . . . . . PLG8 . . . . . . . . . 136 810 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 114 066 . . . . CONNECTOR, rect skt 20-14ga Amp 350536-1 . . . . . . . . . . . . . . 4
. . . 20 . . . . Z1 . . . . 1290740009880 . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . 1107430009309 . . FITTING, stl flrd conn M 1/2tbg x .750-16 . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . 1551670009309 . . UPRIGHT, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 601 965 . . SCREW, .375-16 x 1.000hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . . . . . . . . . 017 479 . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . 1551680009309 . . UPRIGHT, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . . . . . . . 134 456 . . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . 1186440009309 . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . . . . . 032 452 . . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . BAT . . . . . . . . . . 012 724 . . BATTERY, stor 12V 550crk 165RSV . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1448270009309 . . INSULATOR ASSEMBLY, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . . . . 010 460 . . STUD, stl .312-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . CR2,4 . . . . . . . . . 090 104 . . RELAY, encl 12VDC SPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG9,10 . . . . . . . . 148 850 . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 32 . . . . . . . . . . . . . . . . . . . 601 851 . . NUT, stl slf lkg hex reg .625-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 33 . . . . . . . . . . . . 1169780009309 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . . . . . 083 553 . . BASE, filter fuel w/adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . . . . . 145 281 . . FITTING, hose brs barb elb M 3/8tbg x 1/4NPT . . . . . . . . . . . . . . . . 2
. . . 36 . . . . . . . . . . . . . . . . . . . 099 542 . . CLAMP, hose .645-.828clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 37 . . . . . . . . . . . . . . . . . . . 134 836 . . HOSE, SAE .375 ID x .620 OD (order by ft) . . . . . . . . . . . . . . . . . . . 7ft
. . . . . . . . . . . . . . . . . . . . . . . . . 023 562 . . CLAMP, hose .312-.875clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . . . . . . . 117 227 . . BRACKET, mtg fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . . . . *062 342 . . SEPARATOR, fuel filter & water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . . . . . 089 120 . . CLAMP, hose .375-.450clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . . . . . . 073 433 . . FITTING, brs barbed M 3/16tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . 2
. . . 42 . . . . . . . . . . . . 1194860009309 . . TUBE, pick-up fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 43 . . . . 2T . . . . . . . . . . . 163 656 . . BLOCK, term 65A 12P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . 0570560009309 . . BRACKET, mtg term strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . . . . . . 081 646 . . FITTING, brs barbed M 3/8tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . . . . . . 146 357 . . SENDER, fuel gauge 11.000 deep . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . . . . . . 121 823 . . LABEL, warning do not lift from this end . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . . . . . . 010 678 . . FITTING, pipe brs elb st 1/4NPT LH . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-166 941 Page 39
Item Dia. Part
Figure 11-1A. Main Assembly (Continued)
. . . 49 . . . . . . . . . . . . . . . . . . . 073 433 . . FITTING, brs barbed M 3/16tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . 1

. . . 50 . . . . . . . . . . . . 0456660009309 . . LATCH, door snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 51 . . . . . . . . . . . . 1187900009309 . . ANGLE, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . . . . . . 010 914 . . HANGER, minerallic No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . . . . . . 087 341 . . BUMPER, door 1.000 OD x .750 high . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 54 . . . . . . . . . . . . 1551660009309 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 121 699 . . SPACER, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . 601 965 . . SCREW, .375-16 x 1.000hexhd (used on fuel filter bracket also) . 4
. . . . . . . . . . . . . . . . . . . . . . . . . 602 213 . . WASHER, lock stl split .375 (used on fuel filter bracket also) . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . 601 871 . . NUT, stl hex jam .375-16 (used on fuel filter bracket also) . . . . . . . 4
. . . 55 . . . . . . . . . . . . 1311880009309 . . FRAME, mtg reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 007 025 . . SCREW, cap stl hexhd .625-11 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . 602 218 . . WASHER, lock stl split .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . 085 980 . . NUT, stl hex full fnsh .625-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 56 . . . . . . . . . . . . 1311270009309 . . BRACKET, rect RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . SR3 . . . . . . . . . . 142 507 . . RECTIFIER, si 3ph 450A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . 1448180009309 . . BUS BAR, rectifier AC to AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 58 . . . . . . . . . . . . . . . . . . . 030 170 . . BUSHING, snap-in nyl .750 ID x 1.000mtg hole . . . . . . . . . . . . . . . . 1
. . . 59 . . . RC12 . . . . . . . . . 047 637 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 079 534 . . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . . 14
. . . 60 . . . . . . . . . . . . 1215410009309 . . BRACKET, rect LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . . . . . . 026 947 . . STAND-OFF, insul .250-20 x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 62 . . . . . . . . . . . . 1376100009309 . . BUS BAR, neg term to rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . . . . . . 079 739 . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 . . . . . . . . 2
. . . 64 . . . PLG6 . . . . . . . . . 048 598 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . . . . . . Fig 11-4 . . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . . . . . . Fig 11-3 . . PANEL, lower front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . . . . . . 122 354 . . GUARD, splash fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . . . . . . 107 343 . . GROMMET, rbr neck filter fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . 0240350009309 . . CAP, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . 1448230010202 . . DOOR, front lower RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . . . . . . 147 911 . . PLATE, ident diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . . . . . . 134 792 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . 1448210009309 . . WINDOW, door lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1448220009309 . . FRAME, support window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . +1292260010202 . . DOOR, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . . . . . . Fig 11-2 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . . . . . . 131 125 . . SHIELD, heat lower LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . . . . . . 131 124 . . SHIELD, heat lower RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . 1312430009309 . . BUS BAR, pos term to rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . 1317500009309 . . BUS BAR, shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 120 188 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 136 615 . . LABEL, caution refer to Owner’s Manual . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 164 617 . . CLIP, wiring straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . 164 616 . . CLIP, wiring offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 135 784 . . CLIP, conduit convoluted 3/4 in 6.35mm mtg hole . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . 149 616 . . CLAMP, stl cush .187dia x .344mtg hole . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 127 854 . . CLAMP, stl cush 1.312dia x .343mtg hole . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . 089 256 . . CLAMP, stl cush 1.750dia x .531mtg hole . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 010 143 . . CLAMP, nyl .375 clamp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-166 941 Page 40
Item Dia. Part
Figure 11-1B. Main Assembly
... 1 . . . . . . . . . . . . 1448720009309 . . BAFFLE, air upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . . . . . . 006 086 . . BLANK, snap-in 1.500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............................. See engine manual for replacement parts
... 4 . . . . . . . . . . . . 1448200009309 . . BRACKET, mtg air line to alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . . . . . . 138 098 . . HOSE, sst brd 20.750 lg 3/4NPT M ftg x 3/4NPT M INV
(same as Item 13 Fig 11-1A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . . . . 192 197 . . BRACKET, mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . 1187060009309 . . AIR LINE, tank to exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . . . . . 023 313 . . CLAMP, hose 3.250-3.000clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . . . . 162 625 . . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . . . . . 010 863 . . CLAMP, hose 2.062-3.000clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 11 . . . . . . . . . . . . 1626660009309 . . TUBING, air cleaner intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . . . . . 073 655 . . FITTING, pipe brs nipple hex 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . S11 . . . . . . . . . . 118 067 . . SWITCH, vacuum air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . 1371640009309 . . HOSE, air input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . . . . . 010 497 . . CLAMP, hose .750 − 1.750clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 16 . . . . . . . . . . . . 1183490009309 . . AIR LINE, compressor to tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . 1448300009309 . . FITTING, pipe brs adapter M 3/4NPSM x 26mm x 1.5 . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . 1448310009309 . . SEAL, ring copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . 1371790009309 . . AIR COMPRESSOR, 300cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . 1261620009309 . . SHIELD, heat compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . . . . 151 734 . . ENGINE, Deutz dsl elec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1065390009309 . . O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1065380009146 . . STARTER, engine 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 164 618 . . SHUTDOWN KIT, rsv type governor . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . 1528460009309 . . HOSE, air cleaner elb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . 1532490009309 . . BAFFLE, upper air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . 1142710009309 . . COMPOUND, sealant material (order by ft) . . . . . . . . . . . . . . . . . . . 5ft
. . . 25 . . . . . . . . . . . +1528530010202 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . 1174860010202 . . PIPE, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . . . . . 122 382 . . CAP, rain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . . . . . 108 487 . . LABEL, warning falling equipment can cause serious injury . . . . . . 2
. . . 29 . . . . . . . . . . . . . . . . . . . 163 226 . . AIR CLEANER, intake (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . . . . 021 116 . . . . CAP, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . . . . . 004 115 . . . . BAFFLE, dust cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . . . . . 021 117 . . . . NUT, wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . . . . *020 319 . . . . ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . . . . . 021 114 . . . . CLAMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . . . . . 021 115 . . . . BAND, mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . 1528450009309 . . HOSE, air cleaner elb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . 0280890010202 . . DOOR, access radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . . . . . . 147 913 . . PLATE, ident engine lube oil only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 147 912 . . PLATE, ident oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . . . . . 089 178 . . GROMMET, rbr 3.000 ID x 3.500mtg hole . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . . . . . 049 170 . . GROMMET, rbr 2.500 ID x 2.750mtg hole . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . . . . . . 004 130 . . BRACKET, support door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . 1214130010202 . . PANEL, end baffle air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . +1453150010202 . . DOOR, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1311870010202 . . PANEL, engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 146 389 . . LABEL, diesel engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . . . . . . 147 923 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . 2
. . . 45 . . . . . . . . . . . . . . . . . . . 119 861 . . LATCH, paddle series 300 w/lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . 1198510010202 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . 1172190010202 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 48 . . . . . . . . . . . . . . . . . . . 149 971 . . FITTING, pipe brs adapter bhd 1/2NPT x 1.500 lg . . . . . . . . . . . . . . 1
OM-166 941 Page 41
9 10 36
10 29 35
34
OM-166 941 Page 42

8 11 33
7 32
6 31
30
12
5
1 28 37
15 14 13 38
16 27 39
2
17
3 4 18 40
26
17
41
18
19 25
42
20 23 24
21 22 10
43
74
Figure 11-1B. Main Assembly

44
60 59
58 50
73 45
57 49
56 48
70
69 55 46
61 54 51 47
65 62 53
63
72 64 52
65
66
Fig 11-5 68 67
15
71
ST-800 491-B (2 of 2)
Item Dia. Part
Figure 11-1B. Main Assembly (Continued)
... 49 . . . . . . . . . . . . . . . . . . . 089 351 .. FITTING, pipe brs plug hexhd 1/2NPT . . . . . . . . . . . . . . . . . . . . . . . . 1

... 50 . . . . . . . . . . . . 1532480009309 .. BAFFLE, lower air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 51 . . . . . . . . . . . . 1528480009309 .. BRACKET, oil neck w/cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 52 . . . . . . . . . . . . 1528520009309 .. PIPE, oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 53 . . . . . . . . . . . . . . . . . . . 071 890 .. RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 54 . . . . . . . . . . . . 1529040009309 .. CLAMP, hose 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 55 . . . . . . . . . . . . 1528470009309 .. HOSE, oil filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 56 . . . . . . . . . . . . . . . . . . . 071 730 .. TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . 4
... 57 . . . . . . . . . . . . . . . . . . . 602 246 .. WASHER, flat stl std .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 58 . . . . . . . . . . . . . . . . . . . 071 731 .. WASHER, flat stl .656 ID x 2.250 OD . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 59 . . . . . . . . . . . . . . . . . . . 601 945 .. SCREW, cap stl hexhd .625-18 x 4.000 . . . . . . . . . . . . . . . . . . . . . . . 4
... 60 . . . . . . . . . . . . . . . . . . . 116 707 .. SUPPORT, front engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 61 . . . . . . . . . . . . . . . . . . . 603 110 .. HOSE, nprn .500 ID x .687 OD (order by ft) . . . . . . . . . . . . . . . . . . . 2ft
... 62 . . . . . . . . . . . . . . . . . . . 010 858 .. CLAMP, hose .500-.906clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 63 . . . . . . . . . . . . 0395990009309 .. FITTING, brs barbed M 1/2tbg x 1/2NPT . . . . . . . . . . . . . . . . . . . . . . 1
... 64 . . . . . . . . . . . . . . . . . . . 088 684 .. VALVE, ball bronze 1/2thd female . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 65 . . . . . . . . . . . . 1063940009309 .. FITTING, stl flrd conn M 1/2tbg x 1/2tbg . . . . . . . . . . . . . . . . . . . . . . 2
... 66 . . . . . . . . . . . . 1178270009309 .. FITTING, pipe stl tee F 1/2NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 67 . . . . . . . . . . . . 1107430009309 .. FITTING, brs flrd conn M hd 1/4tbg x 1/8NPT . . . . . . . . . . . . . . . . . 1
... 68 . . . . . . . . . . . . 1355720009309 .. HOSE, oil 47.000 3/4 swivel both ends
(same as Item 29 Fig 11-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . . . . . . 118 452 . . FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . . . . . . 131 208 . . STOP, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . 1448100009309 . . HOSE, cooling compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . . . . . . Fig 11-5 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . 1448640009309 . . BAFFLE, air lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . . . . . . 132 712 . . PIPE, muffler extension elb 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 119 836 . . TUBING, stl .875 OD x .563 ID x .875 lg . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . ♦041 481 . . STARTING AID, diesel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . ES1 . . . . . . . . . ♦034 074 . . . . VALVE, ether (diesel starting aid) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . ♦083 859 . . . . BRACKET, mtg fuel filter/quick start . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . ♦195 754 . . . . ADAPTER, atomizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . ♦046 410 . . . . ATOMIZER, .125 L elbow orf 12 o’clock from inlet . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . ♦035 325 . . . . LABEL, ether starting aid caution etc . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . S8 . . . . . . . . . . ♦021 467 . . . . SWITCH, tgl SPST 3A 250V off-none-(on) spd term . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . ♦021 385 . . . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . ♦020 185 . . . . FITTING, pipe brs elbow st 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL
OM-166 941 Page 43

1
3* 5
6
24 25
7
23
22
21
8
20
4 10
19
9
11
18 17 16 15
14 12 ST-800 490-A
13
*Includes Item 4
Figure 11-2. Panel, Front w/Components
OM-166 941 Page 44

Item Dia. Part
Figure 11-2. Panel, Front w/Components (Fig 11-1A Item 75)
. . . 1 . . . . S9 . . . . 1346300009880 . . SWITCH, range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . 1183400010202 . . PANEL, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . R1 . . . . . . . . . . . 072 462 . . POTENTIOMETER, w/shaft lock (consisting of) . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . . . . 072 590 . . . . LOCK, shaft pot .375-32 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . S4 . . . . . . . . . . . 011 611 . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . S5 . . . . . . . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . S1 . . . . . . . . . . . 172 070 . . SWITCH, ignition 5posn w/out handle . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . . . . . 021 385 . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and NSPR number) . 1
. . . 10 . . . . . . . . . . . . . . . . . . . 125 707 . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . FG . . . . . . . . . . 118 066 . . GAUGE, fuel elec 12V neg grd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . V2 . . . . . . . . . . . 164 747 . . METER, volt batt chg 8-18 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . OG . . . . . . . . . . 129 870 . . GAUGE, pressure oil 25-30PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 128 829 . . KIT, oil line 44.000 in 1/8NPT x 10mm . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . 1298370009309 . . GAUGE/SWITCH, temp oil mech 300deg setting . . . . . . . . . . . . . . 1
. . . 15 . . . . HM . . . . . . . . . . 118 058 . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . . . . 082 788 . . HOLDER, light ind only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . PL1,3 . . . . . . . . *048 155 . . BULB, incand flg base 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . . . . . . 082 789 . . LENS, light ind red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . . . . . 097 926 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . . . . . 010 647 . . PIN, spring .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . . . . 090 231 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . A2 . . . . . . . . . . . 164 875 . . METER, amp DC 50MV 0-1K scale . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . V1 . . . . . . . . . . . 164 872 . . METER, volt DC 0-100 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and NSPR number) . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . . 022 289 . . TUBING, stl .312 OD x .187 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

OM-166 941 Page 45

9
2
8
1 7 10 11
6
5
4
3
2
12 13
14
10
15 16
1
31
30
17
27 28 29
18
26 19
20
23 22 21
25 24 ST-147 320-F
Figure 11-3. Panel, Lower Front w/Components
OM-166 941 Page 46

Item Dia. Part
Figure 11-3. Panel, Lower Front w/Components

(Fig 11-1A Item 66)
. . . 1 . . . . . . . . . . . . 0386120009309 . . TERMINAL ASSEMBLY, pwr output (consisting of) . . . . . . . . . . . . . 2

. . . 2 . . . . . . . . . . . . . . . . . . . 601 840 . . . . NUT, brs hex .500-13 jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 3 . . . . . . . . . . . . . . . . . . . 601 839 . . . . NUT, brs hex .500-13 full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . . . . . . 038 847 . . . . BUS BAR, term pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . Neg/Pos . . . . . . . . 038 613 . . . . TERMINAL BOARD, pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . . . . 038 900 . . . . STUD, brs .500-13 x 2.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . . . . . 602 247 . . . . WASHER, flat stl SAE .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . . . . . 605 787 . . . . WASHER, lock stl intl tooth .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . C1,2 . . . . . . . . . . 085 321 . . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 601 976 . . SCREW, cap stl hexhd .500-13 x 1.500 (bus bar to terminal) . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . 044 942 . . NUT, locking .500-13 (bus bar to terminal) . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . . . . . . 097 132 . . STAND-OFF, 6-32 x .375 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 11 . . . . PC3 . . . . . . . . . . 150 415 . . CIRCUIT CARD, connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG3-5 . . . . . . . . 165 668 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 3
. . . 12 . . VR1/R4 . . . . . . . . 046 819 . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . RC3 . . . . . . . . . . 085 302 . . CONNECTOR, circ 9skt rcpt Amphenol MS-3102A-20-16S . . . . . . 1
. . . 14 . . . . CB3 . . . . . . . . . . 083 432 . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . PC4 . . . . . . . . . . 152 966 . . CIRCUIT CARD, filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CB1 . . . 1532470009309 . . CIRCUIT BREAKER, mag SPDT 30A 250VAC . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . 1502670009309 . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . . . . . 083 030 . . STUD, brs grd .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . . . . . 010 915 . . WASHER, flat brs .250 ID x .625 OD . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 20 . . . . . . . . . . . . . . . . . . . 601 836 . . NUT, brs hex .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 21 . . . . . . . . . . . . 0918600009309 . . STRAIN RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . . . . . 010 916 . . CONNECTOR, clamp cable .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . 3T . . . . . . . . . . . 073 873 . . BLOCK, term 30A 14P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . . . . . 022 289 . . TUBING, stl .312 OD x .187 ID x .437 lg . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . 1482370009309 . . COVER, terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . 1479080009309 . . GAUGE, oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . 1224460009309 . . FITTING, pipe galv nipple .500NPT x 1.500 lg . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . 0886900009309 . . FITTING, stl flrd elbow fem 1/2tbg x 1/2NPT . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . 1355720009309 . . HOSE, oil 47.000 3/4 swivel both ends
(same as Item 70 Fig 11-1B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . . . . 039 885 . . CONNECTOR, circ protective cap Amphenol 9760-20 . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating lower
(order by model and NSPR number) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1577780009309 . . STRAP, grounding (front panel to base) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1577920009309 . . STRAP, grounding (front panel to control box) . . . . . . . . . . . . . . . . . 1
OM-166 941 Page 47

Item Dia. Part
Figure 11-4. Control Box (Fig 11-1A Item 65)

. . . 1 . . . . . . . . . . . . 1186380009309 . . ENCLOSURE, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . T1 . . . . 0700700009309 . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . RC6 . . . . . . . . . . 090 246 . . CONNECTOR w/PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 079 535 . . . . CONNECTOR, circ pin push-in 14-18ga Amp 66359-6 . . . . . . . . 16
. . . 4 . . . . RC7 . . . . . . . . . . 047 637 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . D1 . . . . . . . . . . . 189 701 . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . 1562370009309 . . BRACKET, holding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . 1T . . . . . . . . . . . 098 828 . . BLOCK, term, 10A 10P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . . . . . 129 524 . . TERMINAL, frict .250 x .032 uninsul male . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . . . . 110 375 . . STAND-OFF SUPPORT, PC card No. 6 screw . . . . . . . . . . . . . . . . . 8
. . . 10 . . . . PC2 . . . . . . . . . . 160 888 . . CIRCUIT CARD, voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . PC1 . . . 1337570009309 . . CIRCUIT CARD, field current regulator . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CR1 . . . . . . . . . . 044 588 . . RELAY, encl 12VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CR3 . . . . . . . . . . 059 268 . . RELAY, encl 120VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . SR2 . . . . . . . . . . 097 353 . . DIODE/SCR, bridge intg 2SCR 3 diodes . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . MS1 . . . . . . . . . . 118 072 . . SWITCH, magnetic shutdown 12VDC (consisting of) . . . . . . . . . . . 1
. . . 16 . . . . . F . . . . . . . . . . *048 317 . . . . FUSE, mintr gl 14A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 045 852 . . CLIP, component .687dia mtg adh back . . . . . . . . . . . . . . . . . . . . . . . 1
1
16
15 14
13
12 2
8
9
11
7 6
5 4 3
10 ST-800 489
Figure 11-4. Control Box

OM-166 941 Page 48
Item Part
No. No. Description Quantity
Figure 11-5. Generator (Fig 11-1B Item 72)
... 1 . . . . . . . . . . . . . . . 018 614 . . BRUSH SET, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

... 2 . . . . . . . . . . . . . . *151 299 . . . . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . . 600 270 . . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . . 152 044 . . . . CAP, brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . . 049 650 . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . 2
... 7 . . . . . . . . . . . . . . +140 096 . . STATOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . . . 039 207 . . . . BAFFLE, air generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . . . 083 751 . . ROTOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . . 024 617 . . . . RING, retaining external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . . . 053 390 . . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . . 083 748 . . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . 1450210009309 . . STATOR, exciter/endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . . . 601 965 . . SCREW, .375-16 x 1.000hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
... 15 . . . . . . . . . . . . . . . 153 299 . . ENDBELL, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . . . . . . . . . . . . 143 220 . . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . . . . . . . . . . . . . 004 203 . . STRIP, nyl .050 x 4.000 x 9.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12
9
11
7 10
8
6
1
4
3
2
5
13
16 14
17 15 SD-134 503-C
Figure 11-5. Generator

OM-166 941 Page 49
AVW – 300/301 Manual Part Appx D
Appendix D – Applicable CB&I Documents Page 1
Appendix D – CB&I Reference Documents
High Wind Stabilizing – Construction Manual 13
Excerpt from Construction Manual 13 Section 3.9
See latest revision of Construction Manual 13.
3.9 WIND PROTECTION
Precautions against wind damage will vary with tank location, tank size and time of year. Local
knowledge must be used to determine the protection to be provided over and above the minimum
requirements, but when winds are expected to regularly exceed 25 mph (40 kph) see paragraph
3.9.2, which lists additional measures to be taken in the event of higher winds. Judgment is the
best guideline available to determine how much protection is necessary. The Construction
Manager and Construction Supervisor must be sure the superintendents have and use adequate
equipment during seasons of expected high winds. The superintendents must stay reasonably
aware of local weather forecasts so they can be ready to use the available equipment when storms
are expected.
3.9.1 Minimum Wind Protection Requirements:
The following items are minimum requirements, which are to be followed when working in
moderately windy or calm conditions.
a. When heavy equipment such as the AGW or AVW and MPS is being supported on the
shell, precautions must be taken to prevent the equipment from causing the shell to blow in
due to high winds.
1) When the AGW and/or AVW with or without MPS units are on the shell and the
shell is no more than three rings high, the equipment may stay on the shell
overnight without guying. If instability is detected follow 2) or 3) below.
2) When just the AGW and/or AVW are on the shell (fourth ring and higher), a single
3/8" cable guy inside and outside should be put on the shell at both the AGW and
AVW, every night. In lieu of guying the shell, the AGW or AVW may be removed
from the shell and suspended above ground overnight on a second ring hitch lug or
be suspended from a non-hydraulic crane. Hydraulic rigs can leak down.
3) When using the AGW and/or AVW with MPS units, when the shell is four rings and
higher, the MPS units must be disconnected from the AGW or AVW and set on the
ground every night because of the weight. If it is not practical or economical to set
the MPS units on the ground, the Construction Supervisor must get approval from
the local Construction Manager to leave the MPS units on the shell over night and
the following must be done:
(a) The shell ring that the equipment is setting on must be fully erected, partially
welded, and completely fit - full circumference. The next higher ring may be
partially erected due to spiraling the shell.
(b) Two 3/8" diameter cable guy lines must be attached to the shell adjacent to
the equipment inside and outside (4 total) and tightened every night. This is
4 guys for the AGW and 4 for the AVW. See Fig. 3-15.
4) With the AVW, the MPS must always be oriented with the generator and welding
machine on the outside of the shell to avoid an inward moment on the shell. When
the AVW is on the inside, always put the MPS on the shell first and remove it last.
Extra weight, such as a propane bottle, should go outside.
Fig. 3-15 AGW & MPS on shell over night - ONLY WITH CONST. MGR. APPROVAL.
Automatic Vertical Welding (AVW) Technique Requirements – CMS-830-15-GL-11021
See CMS for latest revision.
GUIDELINES
Guideline Automatic Vertical Welding (AVW) CMS

Title: Number: CMS-830-15-GL-11021
Technique Requirements
Guideline Issuing Manager Corporate Welding
Owner: Corporate Welding Technology Authority:
Technology
AUTOMATIC VERTICAL WELDING (AVW)

TECHNIQUE REQUIREMENTS
0 Issued for Use TJL 20 Jan 2009

Rev Changes Approved Date
UNCONTROLLED COPY IF PRINTED Page 1 of 8

"©Chicago Bridge & Iron Company, 2009. All Rights Reserved. For Internal Use Only.
NOTICE: THIS DOCUMENT, AND ALL TEXT, DRAWINGS, DETAILS AND DATA SHOWN HERETO, IS THE SOLE PROPERTY OF
CHICAGO BRIDGE & IRON COMPANY, AND SHALL NOT BE REPRODUCED IN ANY MANNER, USED FOR ANY PURPOSE
WHATSOEVER, OR RELEASED TO ANYONE EXCEPT BY EXPRESS WRITTEN PERMISSION OF CHICAGO BRIDGE & IRON
COMPANY."
GUIDELINES CMS Number:
CMS-830-15-GL-11021
Revision:
Automatic Vertical Welding
0
(AVW) Technique Requirements
Approval Date:
20 Jan 2009
0.1 Scope: This guideline gives basic techniques for welding with CB&I automatic vert welding equipment
(AVW).
0.2 Introduction: The CB&I AVW welding techniques are electrogas welding process (EGW). The CB&I
AVW processes utilize both single pass and multi-pass techniques, producing fast, sound, high quality
welds, in a thickness range of steels from 3/8" to 4 inches. (9.5 to 101.6 mm).
1.0 AUTOMATIC VERTICAL TECHNIQUE:

1.1 Recommended Joint Details are shown in CMS-830-15-WI-13012.
1.2 Equipment Operating Instruction: Refer to CONSTRUCTION MANUAL 201.
1.2.1 Equipment Operating Parameters: When welding with Lincoln NR-431 self shielding
electrode, in the steel thickness range of 3/8" to 1 1/8 inches (9.5 to 28.5 mm), there
are two joint details available. A SINGLE PASS/SINGLE VEE detail in which all
welding is from one side with the backside finished after the AVW pass (Refer to Table
1.0) and a MULTI-PASS/SINGLE VEE detail which requires back-gouging and hand
welding on the backside (Refer to Table 2.0). Steel thickness in the range of 1 3/16" to
3 inches (30.2 to 76.2 mm) a MULTI-PASS/DOUBLE VEE joint detail is used utilizing
the AVW process on both sides, refer to Table 3.0.
When welding with electrodes which require CO2 shielding gas, refer to Table 4.0 and
Table 5.0 for welding parameters.
The selection of the joint detail and type of welding parameters used is sometimes
dependent upon code requirements and client specifications, if deviations from these
guidelines are required by them, the contract welding procedure will specify joint detail,
wire type and welding parameters to be used and must be followed.
1.3 The equipment lends itself to a variety of gaps and joint widths. Caution must be exercised to
avoid opening the gap too much or the metallurgical advantages of the AVW and technique
may be lost.
Anytime a specified gap must be increased over 1/16" (1.5mm) wide due to shortage of steel, it
will be necessary to build the plate edges up by manual welding, or to have a larger root pass
applied in the joint so that, when the automatic vertical welding is performed, the heat input will
not be increased enough to cause coarsening of the grain in either the weld or the heat
affected zone.
Gaps which are smaller than specified will cause erratic operation of the AVW and loss of
technique causing excess repair and manual welding.
1.4 Copper Back-Up Shoes, Copper Water Cooled Tube or Ceramic Inserts are normally the
materials which are to be used to back up an AVW weld. See CONSTRUCTION MANUAL 201
for details. In special applications a mild steel backup bar having a chemistry similar to the
parent plate is used. Never use concrete reinforcing bars because they may have high carbon
and sulphur contents. CMS - 830-17-WI-10001 (Expendable Construction Material) specifies
acceptable material for use as a back-up bar.
1.5 All starts and stops must be arc-air gouged to clean weld metal. Use shielded metal arc
welding (SMAW) or flux cored arc welding (FCAW) processes to make repairs and build up.
2.0 INSPECTION REQUIREMENTS

See CMS-830-15-WI-40002 thru CMS-830-15-WI-40010 for CB&I and code minimum inspection
requirements when automatic vertical welding (AVW) is performed.
3.0 ELECTRODE STORAGE AND CARE

3.1 Storage

CMS-830-15-GL-11021
Revision:
0
Approval Date:
20 Jan 2009
AVW electrodes must be stored in a place preferably on a pallet and a few inches away from
any walls to allow free air circulation of air around and under the cartons of electrode. AVW
electrodes in the original unopened boxes will remain dry indefinitely under normal storage
conditions.
3.2 Care of AVW Electrodes
Electrodes may be left mounted on the AVW overnite if properly covered or wrapped to protect
from rain or moisture, to. Electrode which has rusted must be spooled off to clean electrode or
discarded.

CMS-830-15-GL-11021
Revision:
0
Approval Date:
20 Jan 2009

CMS-830-15-GL-11021
Revision:
0
Approval Date:
20 Jan 2009

CMS-830-15-GL-11021
Revision:
0
Approval Date:
20 Jan 2009

CMS-830-15-GL-11021
Revision:
0
Approval Date:
20 Jan 2009

CMS-830-15-GL-11021
Revision:
0
Approval Date:
20 Jan 2009
(Plate Structures – Modified Format)

AVW – 300/301 Manual Part Appx E
Appendix E – Joint Fit-Up / Technique Page 1
Appendix E – Joint Fit-Up / Technique
Gap
All gaps must be maintained according to the joint design to be used; be it either
standard joint design with backside gouged or joint design for one sided welding.
It is important to remember that a gap that is too narrow will cause lack of
penetration, extra arc gouging and extra hand welding using a standard joint
design. A gap that is too narrow using a joint design for one sided welding will
result in a lack of penetration and loss of consistent back side bead shape,
requiring pickups. In both cases, it will make it difficult to control the weld due to
the reduced joint area.
Since the AVW equipment is gap sensitive, it is very important to fit the vertical
joints using the gap shown on the contract drawings as described below. It has
been found from experience that the gap at the top of the vertical joint increases
as welding progresses along the joint. To compensate for the increase in gap,
the joint gap is to be fit as follows:
 The top of the verts are to be fit with a gap 1/32 inch to 1/16 inch (.80 to 1.6
mm) less than specified on the contract drawing.
 A 6 foot (1829mm) level is to be used when fitting the verts. By varying the
gap as stated above. The vert will lean in slightly after fit-up.
 After the vert is welded, check again using the 6 foot (1829mm) level. The
top of the vert should have moved out slightly and the vert should be plumb.
If not, the gap should be adjusted on subsequent weld joints so that the vert
will be plumb after welding. If a 6 foot level is not available, the gap can be
checked by measuring between 4 reference lines scribed on the shell
plates (Figure A1).
 Scribe 4 vertical lines on the plates to be welded. Each line should be
located 2” (50.8mm) in from the plate edge. Scribe one pair of lines about
6” (152mm) up from the bottom of the vert.
 Measure the distance between each pair of lines before the vert is welded
(remember that the gap will be slightly less at the top of the vert)
 Measure the distance between each pair of lines after the vert is welded
and compare the top measurements taken before the vert was welded. If
these 2 measurements are the same, no adjustment in the gap will be
necessary on subsequent verts. If these 2 measurements at the top of the
vert are closer together than the ones at the bottom, the gap at the top of
the vert will need to be increased accordingly. For example, if the lines are
closer together at the top than at the bottom, the gap at the top of the vert
will need to be increased accordingly.
Figure E1
For a double bevel joint design, the first side welded will not move unless there
are several stops and starts. There is a tendency for the vert to move slightly
when the second side is welded. Thus, on a flat bottom tank, the joint should be
peaked out slightly and the inside welded first. If the outside is welded first, the
joint should be slightly flat before welding. Such factors as the amount of roll
(over, under) should also be taken into consideration.
a. Peaking
For single pass welds, the vert will not move during welding; therefore, the vert
should be fit to the correct radius.
b. Cleaning
Normal wire brushing to remove dirt will generally be satisfactory on both sides of
the vert. Care should be taken to remove all burrs from both sides of the plate
surface adjacent to the joint to prevent the moving shoe from hanging up and
allow good contact to the shell with the rear shoe. Any mill scale 1/8” (3.2mm)
within the plate edge must be removed by grinding.
c. Back-up Bar Holding Lugs

A spacer plate must be used between the bull pin and copper back-up bars at all
holding lugs and key plates to prevent damage to the back-up bar. A spacer
plate that is fabricated to the dimensions below (Figure A2) will not fall out after
the bull pin is removed and will allow greater ease in alignment of the back-up
bars.
Figure E2
The top rear holding lug should be at least 4” (102mm) below the top of the vert
to enable the machine to pass.
Figure E3 – 2N22 Key Plate for AVW
To fit the copper backup shoe in place a 2N22-A key plate is to be used or a
standard key plate (drawing 2N8-7) may be modified per the dimensions in
standard drawing 2N22-2. Any modifications should be done in the warehouse, if
possible.
Whenever possible, the weld should be started at the bottom of the vert. In some
cases, however (such as the first ring on a flat bottom tank), the AVW weld
needs to be started 10”-20” (254-508mm) up from the bottom of the vert. The
following figures show the recommended keyplate and lug layout for both cases.
In the case of welding the first ring shell plates, the lower 10”-20” (254-508mm) of
the vert must be welded by hand since the AVW cannot be started at the very
bottom of the joint. This can result in the bulging or “toeing in” of the bottom of
the vert. This condition can be reduced by doing the following: Weld 2 nuts on
the bottom of the annular plate / sketch plate, one on each side of the vert and
then, using bull pins, push out and hold the lower part of the vert with a slight
strain. Once the lower part of the vert is pushed out, weld a heavy finger bar
across the vert about 2-3” (50.8-76.2mm) above the bottom to hold it in place.
Figure A-4 shows a typical keyplate / lug layout for a 10‟-0 (3048mm) shell plate.
A 3 lug arrangement can be used on 8‟-0 (2438mm) shell plates.
Figure E4
Figure E5
The ceramic backup tape is available from:

A. 3MM Company welding back-up, SJ8073-60, Ceramic system.
B. Alloy Rods Corp., Refrac-T-Back, stock no. 69-300018-4,
size1” (25.4 mm) Triangle length 60 degree angle
AVW – 300/301 Manual Part Appx F
Appendix F – Warehouse Setup Page 1
Appendix F – Warehouse Setup
a. Gear Boxes
AVW 301
Item Drawing Description
Horizontal Drive
Motor Baldor Part No. CD3450
2C301-113
Horizontal Drive Gear Electra-Gear Part No.
Box D26AC5375L6/F
Vertical Drive Motor Baldor Part No. CDP3440
Vertical Drive Gear 2C301-80 Electra-Gear Part No.
Box D26AC5375R7/F
AVW 300
Item Drawing Description
Horizontal Drive 1750 RPM DC TEFC – 56C
Motor Frame
2C18-22
Horizontal Drive Gear Electra-Gear Part No.
Box D26AC5375L6/F
1750 RPM DC TEFC – 56C
Vertical Drive Motor Frame
2C18-14
Vertical Drive Gear Electra-Gear Part
Box No.D26AC5375R1/F
Table F1
Note: Change all gear box oil to Synthetic prior to sending out equipment.
b. Wire Feeder Parts List and Information
1. Lincoln LN-10 Wire feeder, Model K1564-4
Model Type Input Power Speed Wire Dia.

K1564-4 Boom Mount 40-42 VAC 35-500 ipm 3/32”
50-750 ipm 1/16”
Table F2
2. LN-10 Accessories
Part Description
KP1505-32 Drive Roll Kit for 3/32” diameter wire
KP1505-16 Drive Roll Kit for 1/16” diameter wire
K162-1 Spindle Adaptor
K1733-1 Wire Straightener
K1520-1 Transformer Kit
K1504-1 Coil Adaptor
M18715-1 Remote Switch Interface Module
K1500-1 Gun Adaptor
Table F3
c. LN-10 Wire feeder: Warehouse setup
i. Install drive roll kit KP1505-32 (3/32” diameter wire) or KP1505-16

(1/16” diameter wire):
1. Turn OFF welding power source.

2. Pull open Pressure Door to expose rolls and wire guides.
3. Remove Outer Wire Guide by turning knurled thumb screws to
unscrew from Feed plate.
4. Remove drive rolls, if any are installed, by pulling straight off the
shaft. Remove inner guide.
5. Insert inner Wire Guide, groove side out, over the two locating
pins in the feed plate.
6. Install each drive roll by pushing over shaft until it butts up against
locating shoulder on the drive roll shaft (DO NOT exceed
maximum wire size rating of the wire drive).
7. Install Outer Wire Guide by sliding over locating pins and
tightening in place.
8. Engage upper drive rolls if they are in the “open” position and
close Pressure Door.
ii. Wire feeder: Setting the DIP Switches
1. The DIP switches are each labeled with an “ON” arrow showing
the on direction for each of the 8 individual switches in each DIP
switch (S1 and S2).
2. Position each switch as shown below, regardless of power source
being used.
DIP Switch S1
DIP Switch S2
Figure F1: Inside LN-10 Panel
DIP Switch S1
Function Switch Position

High Speed
Power Source 1 OFF
Selection 2 OFF
3 OFF
4 OFF
Wire Drive Head 5 ON
Selection 6 ON
7 OFF
8 OFF
Table F4
DIP Switch S2
Function Switch Position

English/Metric 1 OFF
4-step Trigger 2 OFF
Security 3 OFF
Robotics 4 OFF
Limits Setting 5 OFF
Limits Setting 6 OFF
--- 7 ---
--- 8 ---
Table F5
d. Baldor BC154 Motor Control Setup

The motor controls used on the AVW 300 and 301 are Baldor model BC154 with
field installed options BC156 (forward-brake-reverse switch) and BC159 (on/off
AC line switch). The original single turn speed potentiometer is replaced with a
10-turn potentiometer and counting dial. This arrangement is used for both the
vertical and horizontal travel controls on the machine.
Purchased Components
Description Quantity
Baldor BC154 DC Motor Speed Control 1
Baldor BC156 Forward-Brake-Reverse switch kit 1
Baldor BC159 On/Off AC Line Switch kit 1
Armature fuse, 8 Amp. 250 Volt fast acting (Type 2
ABC-8 or equal) (for travel control)
Potentiometer, 5K Ohm, 10-turn 1
(Bourns Part #3540S-1-502 or equal)
Turn counting dial for ¼” Dia. Shaft 1
(Vishay-Spectrol Part #21-1-11 or equal)
Cord Grip CGE-194 & 195 2
Fully insulated terminal, 16 – 14 AWG 3
(Gardner Bender 10-153F or equal
Hook-up wire, 14 AWG, 600V PVC insulation 3 Pcs, 6” long
Table F6
1. Motor Control Assembly Sequence
a) Install cord grips.

b) Remove factory installed start/stop switch.
c) Install BC159 On/Off AC Line switch.
d) Install BC156 Forward-Brake-Reverse switch.
e) Remove factory installed single-turn speed potentiometer.
f) Drill anti-rotation hole for turn counting dial.
g) Install 5K 10-turn potentiometer assembly.
h) Install Turn counting dial.
i) Install armature fuse per table.
j) Set jumpers as listed in Table C8.
Armature fuse table

Motor HP Fuse Rating
Vertical ¾ 12
Horizontal ½ 8
Table F7
2. 2C154 Jumper Setting Table
Jumper Function Setting Setting

Number Vertical Horizontal
J1 Speed/Torque SPD SPD
J2A Input Voltage 115V 115 V
J2B Input Voltage 115V 115 V
J3 Armature Voltage 90V 90 V
J4 Motor Current 7.5 5.0
J5 Current Limit Mode TCL TCL
J6 Tach Generator Voltage 7V 7V
J7 Signal Input Voltage 10V 10 V
Table F8
iii. 10-Turn Potentiometer assembly
Female Fully
Insulated
Disconnect
Terminal
(Typ. 3 Plcs.)
14 AWG Hook-up
wire, 6" long
(Typ. 3 Plcs.)
P2 P1 P3
Potentiometer,
5K Ohm, 10-turn
10-Turn Potentiometer Assembly
Figure F6
e. Programming Rate Meter
 Press the PGM key for 3 seconds.

 Press the PGM key to select the parameter to be edited.
 Press the arrow keys to edit the parameter.
Parameter Value
CALpd 0.0000
CAL 0.2020
dEcP 0000.0
Rate Mode A
Input Type 5 in
Speed 10000
 Press the PGM key for 3 seconds to save and exit program mode.
Note: For additional information see the Rate Meter manual in Appendix D, Section 5.
f. Inbound and Outbound Inspection Checklists
The checklists can be found in Appendix A

AVW Checklist Outbound
AVW Checklist Inbound
The Outbound Checklist must be completed before the unit leaves the warehouse for a jobsite.
The Inbound Checklist may be used (at the discretion of the local warehouse manager) to locate
any major damage to the equipment upon receipt from a jobsite of another warehouse.

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AVW – 300/301 Manual

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AVW – 300/301 Manual Part REV

Revision 3 – June 2011 – JAS

Changed tie off requirement for operator of AVW.

Revision 2 – January 2010 – IH

Revision 1 – June 2009 – NS

Revision 0 – September 1994 – RJK

AVW – 300/301 Manual Part TOC

Table of Contents Page 1

PART 1 INTRODUCTION – 2C300/301 SPECIFICATIONS

PART 2 RECEIVING AND SHIPPING

PART 3 AVW SETUP AND OPERATION

AVW – 300/301 Manual Part TOC

Table of Contents Page 2

5.1 Recommended Electrical Spare Parts

APPENDIX B – APPLICABLE DRAWINGS

APPENDIX C – VENDOR DOCUMENTS

APPENDIX D – CB&I REFERENCE DOCUMENTS

APPENDIX E – JOINT FIT-UP / TECHNIQUE

APPENDIX F – WAREHOUSE SETUP

AVW – 300/301 Manual Part 1

Part 1 Introduction – 2C300/301 Specifications

1.1 Safe Working Loads (SWL)

1.2 Overall Dimensions

Length 86” (2184mm)

Length 86” (2184mm)

Table 1-2 For AVW 301

AVW – 300/301 Manual Part 1

AVW – 300/301 Manual Part 1

AVW – 300/301 Manual Part 1

1.3 Partial Component Product List

See Appendix C for complete detailed product information.

1. Koolant Kooler water pump/cooler

1.4 AVW Applications / Limitations

Weld wire size - 30 – 60 lb coils

AVW – 300/301 Manual Part 2

Receiving and Shipping Page 1

Part 2 Receiving and Shipping

2.1 Packing List

(1) Automatic Vert Welder AVW-300/301.

2.2 Receiving and Setup

Note: The water cooler may be pre-installed in the MPS.

4. Remove the shipping wheel locks shown in Figure 2e.

AVW – 300/301 Manual Part 2

Receiving and Shipping Page 2

Fig. 2-1 Clamping Action

AVW – 300/301 Manual Part 2

Receiving and Shipping Page 3

Fig. 2-2 Prying / Opening Action

2.3 Shipping and Break Down

AVW – 300/301 Manual Part 2

Receiving and Shipping Page 4

Note: Container Interiors may Differ

Figure 2a: Shipping container rails Figure 2b: AVW on rails

Figure 2c: top carriage Figure 2d: bottom carriage

AVW – 300/301 Manual Part 2

Receiving and Shipping Page 5

AVW – 300/301 Manual Part 2

Receiving and Shipping Page 6

2.4 Detailed Load and Unload Instructions