OM-497 197 760AR

September 2003
Processes
Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

Description

Engine Driven Welding Generator

Big Blue 302D


Big Blue 452D

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 9001:2000 Quality Warranty and service information for your
System 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 catalog 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 7/03
 TABLE OF CONTENTS

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

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 7
2-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Warning Label Definitions (For Wordless Labels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Manufacturer’s Rating Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-3. Volt-Ampere Curves For CC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-4. Volt-Ampere Curves For CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-5. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-7. Standard AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-8. Optional Three-Phase Generator Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-1. Installing Welding Generator (See Sections 5-2 And 5-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-2. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-5. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-6. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-7. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models . . . . . . . . . . . . . . . . . . . . . 28
5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-1. Front Panel Controls For CC Models (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-3. Remote Amperage Control On CC Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-4. Weld Control/Arc Condition Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-1. Front Panel Controls For CC/CV Models (See Section 7-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) . . . . . . . . . . . . . . . . . . . . . . 35
7-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
 TABLE OF CONTENTS

SECTION 8 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8-1. 120 Volt And 240 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . 39
8-3. Optional Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 9 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9-6. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9-7. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9-8. Diagnosing Causes Of Engine Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9-9. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SECTION 11 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
OPTIONS AND ACCESSORIES
WARRANTY
 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_10/02
 Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

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

 Marks a special safety message.

This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
 Means “Note”; not safety related. to avoid the hazards.

1-2. Arc Welding Hazards

 The symbols shown below are used throughout this manual to  Use only well-maintained equipment. Repair or replace damaged parts at
call attention to and identify possible hazards. When you see the once. Maintain unit according to manual.
symbol, watch out, and follow the related instructions to avoid the  Wear a safety harness if working above floor level.
hazard. The safety information given below is only a summary of
 Keep all panels and covers securely in place.
the more complete safety information found in the Safety Stan-
dards listed in Section 1-7. Read and follow all Safety Standards.  Clamp work cable with good metal-to-metal contact to workpiece or work-
table as near the weld as practical.
 Only qualified persons should install, operate, maintain, and re-  Insulate work clamp when not connected to workpiece to prevent contact
pair this unit. with any metal object.
 During operation, keep everybody, especially children, away.  Do not connect more than one electrode or work cable to any single weld
output terminal.
SIGNIFICANT DC VOLTAGE exists in inverters after stop-
ELECTRIC SHOCK can kill.
ping engine.
 Stop engine on inverter and discharge input capacitors according to
Touching live electrical parts can cause fatal shocks or
instructions in Maintenance Section before touching any parts.
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In semiautomatic or FUMES AND GASES can be hazardous.
automatic wire welding, the wire, wire reel, drive roll housing, and all metal
parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard. Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
 Do not touch live electrical parts.
 Keep your head out of the fumes. Do not breathe the fumes.
 Wear dry, hole-free insulating gloves and body protection.
 If inside, ventilate the area and/or use exhaust at the arc to remove welding
 Insulate yourself from work and ground using dry insulating mats or covers fumes and gases.
big enough to prevent any physical contact with the work or ground.
 If ventilation is poor, use an approved air-supplied respirator.
 Do not use AC output in damp areas, if movement is confined, or if there is a  Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
danger of falling. instructions for metals, consumables, coatings, cleaners, and degreasers.
 Use AC output ONLY if required for the welding process.  Work in a confined space only if it is well ventilated, or while wearing an air-
 If AC output is required, use remote output control if present on unit. supplied respirator. Always have a trained watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury
 Additional safety precautions are required when any of the following electri- or death. Be sure the breathing air is safe.
cally hazardous conditions are present: in damp locations or while wearing
 Do not weld in locations near degreasing, cleaning, or spraying operations.
wet clothing; on metal structures such as floors, gratings, or scaffolds;
The heat and rays of the arc can react with vapors to form highly toxic and
when in cramped positions such as sitting, kneeling, or lying; or when there
irritating gases.
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order present-  Do not weld on coated metals, such as galvanized, lead, or cadmium plated
ed: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual steel, unless the coating is removed from the weld area, the area is well
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most ventilated, and if necessary, while wearing an air-supplied respirator. The
situations, use of a DC, constant voltage wire welder is recommended. coatings and any metals containing these elements can give off toxic fumes
And, do not work alone! if welded.
 Disconnect input power or stop engine before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29 CFR BUILDUP OF GAS can injure or kill.
1910.147 (see Safety Standards).
 Properly install and ground this equipment according to its Owner’s Manual  Shut off shielding gas supply when not in use.
and national, state, and local codes.  Always ventilate confined spaces or use approved
air-supplied respirator.
 Always verify the supply ground — check and be sure that input power cord
ground wire is properly connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded receptacle outlet.
ARC RAYS can burn eyes and skin.
 When making input connections, attach proper grounding conductor first −
double-check connections.
Arc rays from the welding process produce intense visible
 Frequently inspect input power cord for damage or bare wiring — replace and invisible (ultraviolet and infrared) rays that can burn eyes
cord immediately if damaged — bare wiring can kill. and skin. Sparks fly off from the weld.
 Turn off all equipment when not in use.  Wear a welding helmet fitted with a proper shade of filter to protect your face
 Do not use worn, damaged, undersized, or poorly spliced cables. and eyes from arc rays and sparks when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
 Do not drape cables over your body.  Wear approved safety glasses with side shields under your helmet.
 If earth grounding of the workpiece is required, ground it directly with a sep-  Use protective screens or barriers to protect others from flash and glare;
arate cable. warn others not to watch the arc.
 Do not touch electrode if you are in contact with the work, ground, or anoth-  Wear protective clothing made from durable, flame-resistant material (wool
er electrode from a different machine. and leather) and foot protection.
Return To Table Of Contents OM-497 Page 1
 WELDING can cause fire or explosion. HOT PARTS can cause severe burns.

Welding on closed containers, such as tanks, drums, or  Allow cooling period before maintaining.
pipes, can cause them to blow up. Sparks can fly off from the  Wear protective gloves and clothing when working on
welding arc. The flying sparks, hot workpiece, and hot a hot engine.
equipment can cause fires and burns. Accidental contact of electrode to metal  Do not touch hot engine parts or just-welded parts
objects can cause sparks, explosion, overheating, or fire. Check and be sure bare-handed.
the area is safe before doing any welding.

 Protect yourself and others from flying sparks and hot metal. NOISE can damage hearing.
 Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can damage
 Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not hearing.
possible, tightly cover them with approved covers.
 Wear approved ear protection if noise level is high.
 Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.

 Watch for fire, and keep a fire extinguisher nearby.

MAGNETIC FIELDS can affect pacemakers.

 Be aware that welding on a ceiling, floor, bulkhead, or partition can cause  Pacemaker wearers keep away.
fire on the hidden side.  Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
 Do not weld on closed containers such as tanks, drums, or pipes, unless tions.
they are properly prepared according to AWS F4.1 (see Safety Standards).

 Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and CYLINDERS can explode if damaged.
causing electric shock and fire hazards.

 Do not use welder to thaw frozen pipes. Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
 Remove stick electrode from holder or cut off welding wire at contact tip normally part of the welding process, be sure to treat them
when not in use. carefully.

 Wear oil-free protective garments such as leather gloves, heavy shirt, cuf-  Protect compressed gas cylinders from excessive heat, mechanical
fless trousers, high shoes, and a cap. shocks, slag, open flames, sparks, and arcs.
 Install cylinders in an upright position by securing to a stationary support or
 Remove any combustibles, such as a butane lighter or matches, from your cylinder rack to prevent falling or tipping.
person before doing any welding.
 Keep cylinders away from any welding or other electrical circuits.
 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
 Never drape a welding torch over a gas cylinder.
work and have a fire watcher and extinguisher nearby.
 Never allow a welding electrode to touch any cylinder.
 Never weld on a pressurized cylinder — explosion will result.
 Use only correct shielding gas cylinders, regulators, hoses, and fittings de-
FLYING METAL can injure eyes. signed for the specific application; maintain them and associated parts in
good condition.
 Welding, chipping, wire brushing, and grinding cause
 Turn face away from valve outlet when opening cylinder valve.
sparks and flying metal. As welds cool, they can
throw off slag.  Keep protective cap in place over valve except when cylinder is in use or
 Wear approved safety glasses with side shields even connected for use.
under your welding helmet.  Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND. MOVING PARTS can cause injury.

 Always wear a face shield, rubber gloves, and protec-  Keep away from fans, belts, and rotors.
tive clothing when working on a battery.  Keep all doors, panels, covers, and guards closed
 Stop engine before disconnecting or connecting bat- and securely in place.
tery cables or servicing battery.
 Stop engine before installing or connecting unit.
 Do not allow tools to cause sparks when working on a battery.
 Have only qualified people remove guards or covers for maintenance
 Do not use welder to charge batteries or jump start vehicles. and troubleshooting as necessary.
 Observe correct polarity (+ and −) on batteries.  To prevent accidental starting during servicing, disconnect negative (−)
 Disconnect negative (−) cable first and connect it last. battery cable from battery.
 Keep hands, hair, loose clothing, and tools away from moving parts.
FUEL can cause fire or explosion.  Reinstall panels or guards and close doors when servicing is finished
and before starting engine.
 Stop engine and let it cool off before checking or add-  Before working on generator, remove spark plugs or injectors to keep
ing fuel. engine from kicking back or starting.
 Do not add fuel while smoking or if unit is near any  Block flywheel so that it will not turn while working on generator compo-
sparks or open flames. nents.
 Do not overfill tank — allow room for fuel to expand.
 Do not spill fuel. If fuel is spilled, clean up before starting engine.
 Dispose of rags in a fireproof container.
 Always keep nozzle in contact with tank when fueling.

OM-497 Page 2 Return To Table Of Contents

 STEAM AND HOT COOLANT can burn. BATTERY ACID can BURN SKIN and EYES.

 If possible, check coolant level when engine is cold to  Do not tip battery.
avoid scalding.  Replace damaged battery.
 Always check coolant level at overflow tank, if pres-  Flush eyes and skin immediately with water.
ent on unit, instead of radiator (unless told otherwise
in maintenance section or engine manual).
 If the engine is warm, checking is needed, and there is no overflow tank,
follow the next two statements. ENGINE HEAT can cause fire.
 Wear safety glasses and gloves and put a rag over radiator cap.
 Do not locate unit on, over, or near combustible
 Turn cap slightly and let pressure escape slowly before completely re- surfaces or flammables.
moving cap.
 Keep exhaust and exhaust pipes way from flam-
mables.

ENGINE EXHAUST GASES can kill. EXHAUST SPARKS can cause fire.
 Use equipment outside in open, well-ventilated ar-
 Do not let engine exhaust sparks cause fire.
eas.
 Use approved engine exhaust spark arrestor in re-
 If used in a closed area, vent engine exhaust outside
quired areas — see applicable codes.
and away from any building air intakes.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can HOT METAL from air arc cutting and
cause serious injury or death. gouging can cause fire or explosion.
 Do not use compressed air for breathing.  Do not cut or gouge near flammables.
 Use only for cutting, gouging, and tools.  Watch for fire; keep extinguisher nearby.

COMPRESSED AIR can cause injury. HOT PARTS can cause burns and injury.
 Wear approved safety goggles.  Do not touch hot compressor or air system parts.
 Do not direct air stream toward self or others.  Let system cool down before touching or servicing.

TRAPPED AIR PRESSURE AND WHIPPING

READ INSTRUCTIONS.
HOSES can cause injury.
 Read Owner’s Manual before using or servicing unit.
 Release air pressure from tools and system before
servicing, adding or changing attachments, or open-  Stop engine and release air pressure before
ing compressor oil drain or oil fill cap. servicing.

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

FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING.

 Use lifting eye to lift unit only, NOT running gear, gas  Allow cooling period; follow rated duty cycle.
cylinders, trailer, or any other accessories.  Reduce current or reduce duty cycle before starting
 Use equipment of adequate capacity to lift and to weld again.
support unit.  Do not block or filter airflow to unit.
 If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.

OVERHEATING can damage motors. STATIC (ESD) can damage PC boards.

 Turn off or unplug equipment before starting or stop-
ping engine.  Put on grounded wrist strap BEFORE handling
boards or parts.
 Do not let low voltage and frequency caused by low
engine speed damage electric motors.  Use proper static-proof bags and boxes to store,
move, or ship PC boards.
 Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where
applicable.

FLYING SPARKS can cause injury.

TILTING OF TRAILER can cause injury.
 Wear a face shield to protect eyes and face.
 Shape tungsten electrode only on grinder with proper  Use tongue jack or blocks to support weight.
guards in a safe location wearing proper face, hand,  Properly install welding generator onto trailer accord-
and body protection. ing to instructions supplied with trailer.
 Sparks can cause fires — keep flammables away.

Return To Table Of Contents OM-497 Page 3

 READ INSTRUCTIONS. ARC WELDING can cause interference.
 Use only genuine MILLER/Hobart replacement  Electromagnetic energy can interfere with sensitive
parts. electronic equipment such as microprocessors,
 Perform engine and air compressor (if applicable) computers, and computer-driven equipment such as
maintenance and service according to this manual robots.
and the engine/air compressor (if applicable) manu-  Be sure all equipment in the welding area is electro-
als. magnetically compatible.
 To reduce possible interference, keep weld cables as short as possible,
H.F. RADIATION can cause interference. close together, and down low, such as on the floor.
 Locate welding operation 100 meters from any sensitive electronic
 High-frequency (H.F.) can interfere with radio naviga- equipment.
tion, safety services, computers, and communica-  Be sure this welding machine is installed and grounded according to this
tions equipment. manual.
 Have only qualified persons familiar with electronic  If interference still occurs, the user must take extra measures such as
equipment perform this installation. moving the welding machine, using shielded cables, using line filters, or
 The user is responsible for having a qualified electrician shielding the work area.
promptly correct any interference problem resulting from the installation.
 If notified by the FCC about interference, stop using the equipment at
once.
 Have the installation regularly checked and maintained.
 Keep high-frequency source doors and panels tightly shut, keep spark
gaps at correct setting, and use grounding and shielding to minimize the
possibility of interference.

1-6. California Proposition 65 Warnings

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

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 in Toronto 416-747-4044, website: www.csa-international.org).
(phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11
ting of Containers and Piping, American Welding Society Standard West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi- website: www.ansi.org).
ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire Protec- Standard for Fire Prevention During Welding, Cutting, and Other Hot
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, from National Fire Protection Association,
02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
sparky.org). 617-770-3000, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, OSHA, Occupational Safety and Health Standards for General Indus-
from Compressed Gas Association, 1735 Jefferson Davis Highway, try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website: and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
www.cganet.com). intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
Code for Safety in Welding and Cutting, CSA Standard W117.2, from are 10 Regional Offices—phone for Region 5, Chicago, is
Canadian Standards Association, Standards Sales, 178 Rexdale Bou- 312-353-2220, website: www.osha.gov).

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency To reduce magnetic fields in the workplace, use the following
Electric And Magnetic Fields procedures:
1. Keep cables close together by twisting or taping them.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such 2. Arrange cables to one side and away from the operator.
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from
Research Council concluded that: “The body of evidence, in the operator as practical.
committee’s judgment, has not demonstrated that exposure to power- 5. Connect work clamp to workpiece as close to the weld as
frequency electric and magnetic fields is a human-health hazard.”
possible.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you About Pacemakers:
may wish to minimize your exposure to electromagnetic fields when Pacemaker wearers consult your doctor first. If cleared by your doctor,
welding or cutting. then following the above procedures is recommended.

OM-497 Page 4 Return To Table Of Contents

 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 8/03

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

2-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure Ce groupe de symboles si-
présente des risques de danger ! Ceux-ci sont identifiés par gnifie Mise en garde !
des symboles adjacents aux directives.
Soyez vigilant ! Il y a des
risques de danger reliés
 Identifie un message de sécurité particulier. aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux
PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-des-
 Signifie NOTA ; n’est pas relatif à la sécurité. sous afin de connaître les mesures à prendre pour éviter tout danger.

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

 Les symboles présentés ci-après sont utilisés tout au long du  En effectuant les raccordements d’entrée fixer d’abord le conducteur de
présent manuel pour attirer votre attention et identifier les ris- mise à la terre approprié et contre-vérifier les connexions.
ques de danger. Lorsque vous voyez un symbole, soyez  Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas en-
vigilant et suivez les directives mentionnées afin d’éviter tout dommagé ou dénudé − remplacer le cordon immédiatement s’il est
danger. Les consignes de sécurité présentées ci-après ne font endommagé − un câble dénudé peut provoquer une électrocution.
que résumer l’information contenue dans les normes de sécu-  Mettre l’appareil hors tension quand on ne l’utilise pas.
rité énumérées à la section 2-6 . Veuillez lire et respecter toutes  Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
ces normes de sécurité. mal épissés.
 Ne pas enrouler les câbles autour du corps.
 L’installation, l’utilisation, l’entretien et les réparations ne
 Si la pièce soudée doit être mise à la terre, le faire directement avec un
doivent être confiés qu’à des personnes qualifiées.
câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour.
 Au cours de l’utilisation, tenir toute personne à l’écart et plus  Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
particulièrement les enfants. une électrode provenant d’une autre machine.
 N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
UN CHOC ÉLECTRIQUE peut tuer. manuel.
 Porter un harnais de sécurité quand on travaille en hauteur.
Un simple contact avec des pièces électriques peut  Maintenir solidement en place tous les panneaux et capots.
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès  Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec
que l’appareil est sur ON. Le circuit d’entrée et les circuits la pièce à souder ou la table de travail, le plus près possible de la soudure.
internes de l’appareil sont également sous tension à ce
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le  Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
logement des galets d’entraînement et les pièces métalliques en contact avec avec tout objet métallique.
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la Une tension DC importante subsiste à l’intérieur
terre présentent un danger.
des onduleurs après avoir coupé l’alimentation.
 Ne jamais toucher les pièces électriques sous tension.  Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des compo-
 Porter des gants et des vêtements de protection secs ne comportant pas
sants.
de trous.
 S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens iso- LES FUMÉES ET LES GAZ peuvent
lants suffisamment grands pour empêcher le contact physique éventuel être dangereux.
avec la pièce ou la terre.
 Ne pas se servir de source électrique àcourant électrique dans les zones Le soudage génère des fumées et des gaz. Leur inhalation
humides, dans les endroits confinés ou là où on risque de tomber. peut être dangereux pour votre santé.
 Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.  Eloigner votre tête des fumées. Ne pas respirer les fumées.
 Si l’utilisation d’une source électrique àcourant électrique s’avère néces-  À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de
saire, se servir de la fonction de télécommande si l’appareil en est équipé. l’arc pour l’évacuation des fumées et des gaz de soudage.
 Des précautions de sécurité supplémentaires sont requises dans des envi-  Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
ronnements à risque comme: les endroits humides ou lorsque l’on porte
des vêtements mouillés; sur des structures métalliques au sol, grillages et  Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-
tions du fabricant concernant les métaux, les consommables, les
échafaudages; dans des positions assises, à genoux et allongées; ou
revêtements, les nettoyants et les dégraisseurs.
quand il y a un risque important de contact accidentel avec la pièce ou le
 Travailler dans un espace fermé seulement s’il est bien ventilé ou en por-
sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence:
tant un respirateur à alimentation d’air. Demander toujours à un surveillant
1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
poste à souder manuel (électrode enrobée) DC, 3) un poste à souder ma- peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des
nuel AC avec tension à vide réduite. Dans la plupart des cas, un poste blessures ou des accidents mortels. S’assurer que l’air de respiration ne
courant continu de type CV est recommandé. Et, ne pas travailler seul! présente aucun danger.
 Ne pas souder dans des endroits situés à proximité d’opérations de dé-
 Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation,
à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
 Installer et mettre à la terre correctement cet appareil conformément à son
 Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvani-
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
 Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si néces-
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre saire, en portant un respirateur à alimentation d’air. Les revêtements et
du sectionneur ou que la fiche du cordon est raccordée à une prise tous les métaux renfermant ces éléments peuvent dégager des fumées
correctement mise à la terre. toxiques en cas de soudage.

Revenez à la table des matières OM-497 Page 5

  Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B
LES ACCUMULATIONS DE GAZ ris- pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi-
quent de provoquer des blessures ou mité.
même la mort.
DES PARTICULES VOLANTES
 Fermer l’alimentation du gaz protecteur en cas de peuvent blesser les yeux.
non utilisation.
 Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-  Le soudage, l’écaillement, le passage de la pièce
rateur d’adduction d’air homologué. à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques vo-
LES RAYONS DE L’ARC peuvent pro- lantes. Pendant la période de refroidissement des soudures, elles ris-
quent de projeter du laitier.
voquer des brûlures dans les yeux et  Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
sur la peau.
Le rayonnement de l’arc du procédé de soudage génère DES PIÈCES CHAUDES peuvent
des rayons visibles et invisibles intenses (ultraviolets et provoquer des brûlures graves.
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.  Prévoir une période de refroidissement avant d’effec-
 Porter un casque de soudage muni d’un écran de filtre approprié pour pro- tuer des travaux d’entretien.
téger votre visage et vos yeux pendant le soudage ou pour regarder (voir  Porter des gants et des vêtements de protection pour
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). travailler sur un moteur chaud.
 Porter des protections approuvés pour les oreilles si le niveau sondre est  Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
trop élevé. récemment soudées.
 Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de
l’éblouissement; demander aux autres personnes de ne pas regarder l’arc. LE BRUIT peut affecter l’ouïe.
 Porter des vêtements de protection constitué dans une matière durable, ré-
sistant au feu (laine ou cuir) et une protection des pieds. Le bruit des processus et des équipements peut affecter
l’ouïe.
LE SOUDAGE peut provoquer un in-
 Porter des protections approuvés pour les oreilles si
cendie ou une explosion. le niveau sondre est trop élevé.

Le soudage effectué sur des conteneurs fermés tels que LES CHAMPS MAGNÉTIQUES peuvent
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles peuvent être projetées de affecter les stimulateurs cardiaques.
l’arc de soudure. La projection d’étincelles, des pièces chaudes et des
équipements chauds peut provoquer des incendies et des brûlures. Le contact  Porteurs de stimulateur cardiaque, restez à distance.
accidentel de l’électrode avec des objets métalliques peut provoquer des  Les porteurs d’un stimulateur cardiaque doivent
étincelles, une explosion, un surchauffement ou un incendie. Avant de d’abord consulter leur médecin avant de s’approcher
commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de des opérations de soudage à l’arc, de gougeage ou
danger. de soudage par points.
 Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Si des BOUTEILLES sont endomma-
 Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
gées, elles pourront exploser.
substances inflammables. Des bouteilles de gaz protecteur contiennent du gaz sous
 Déplacer toutes les substances inflammables à une distance de 10,7 m de haute pression. Si une bouteille est endommagée, elle peut
l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec exploser. Du fait que les bouteilles de gaz font normale-
des protections homologués. ment partie du procédé de soudage, les manipuler avec
précaution.
 Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des  Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
ouvertures. chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
 Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. arcs.
 Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-  Placer les bouteilles debout en les fixant dans un support stationnaire ou
clencher un incendie de l’autre côté. dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
 Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-  Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés électriques.
correctement conformément à AWS F4.1 (voir les normes de sécurité).  Ne jamais placer une torche de soudage sur une bouteille à gaz.
 Brancher le câble sur la pièce le plus près possible de la zone de soudage  Une électrode de soudage ne doit jamais entrer en contact avec une bou-
pour éviter le transport du courant sur une longue distance par des che- teille.
mins inconnus éventuels en provoquant des risques d’électrocution et  Ne jamais souder une bouteille pressurisée − risque d’explosion.
d’incendie.
 Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
 Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. raccords convenables pour cette application spécifique; les maintenir ainsi
 En cas de non utilisation, enlever la baguette d’électrode du porte-électro- que les éléments associés en bon état.
de ou couper le fil à la pointe de contact.  Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
 Porter des vêtements de protection dépourvus d’huile tels que des gants  Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
en cuir, une chemise en matériau lourd, des pantalons sans revers, des ou de branchement de la bouteille.
chaussures hautes et un couvre chef.  Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
 Avant de souder, retirer toute substance combustible de vos poches telles les équipements associés et les publication P-1 CGA énumérées dans les
qu’un allumeur au butane ou des allumettes. normes de sécurité.

2-3. Dangers existant en relation avec le moteur

LES ACCUMULATIONS DE GAZ ris- L’ACIDE DE LA BATTERIE peut pro-

quent de provoquer des blessures ou voquer des brûlures dans les YEUX et
même la mort. sur la PEAU.
 Fermer l’alimentation du gaz protecteur en cas de  Ne pas renverser la batterie.
non utilisation.  Remplacer une batterie endommagée.
 Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-  Rincer immédiatement les yeux et la peau à l’eau.
rateur d’adduction d’air homologué.

OM-497 Page 6 Revenez à la table des matières

  Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,
L’EXPLOSION DE LA BATTERIE peut débrancher le câble négatif (−) de batterie de la borne.
RENDRE AVEUGLE.  Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga-
nes mobiles.
 Toujours porter une protection faciale, des gants en  Remettre en place les panneaux ou les dipositifs de protection et fermer les
caoutchouc et vêtements de protection lors d’une in- portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.
tervention sur la batterie.  Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en
 Arrêter le moteur avant de débrancher ou de brancher les câbles de route accidentelle du moteur.
batterie.  Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le
générateur.
 Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie. LA VAPEUR ET LE LIQUIDE DE
 Ne pas utiliser le poste de soudage pour charger les batteries ou des véhi- REFROIDISSEMENT CHAUD peuvent
cules de démarrage rapide.
 Observer la polarité correcte (+ et −) sur les batteries.
provoquer des brûlures.
 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier  Il est préférable de vérifier le liquide de
lieu. refroidissement une fois le moteur refroidi pour éviter
de se brûler.
LE CARBURANT MOTEUR peut pro-
 Toujours vérifier le niveau de liquide de refroidissement dans le vase d’ex-
voquer un incendie ou une explosion. pansion (si présent), et non dans le radiateur (sauf si précisé autrement
dans la section maintenance du manuel du moteur).
 Arrêter le moteur avant de vérifier le niveau de carbu-
 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme sui-
rant ou de faire le plein.
vant :
 Ne pas faire le plein en fumant ou proche d’une sour-
ce d’étincelles ou d’une flamme nue.  Mettre des lunettes de sécurité et des gants, placer un torchon sur le bou-
chon du radiateur.
 Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.  Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
 Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-
rant renversé avant de faire démarrer le moteur. LA CHALEUR DU MOTEUR peut pro-
 Jeter les chiffons dans un récipient ignifuge. voquer un incendie.
DES ORGANES MOBILES peuvent  Ne pas placer l’appareil sur, au-dessus ou à proximité
provoquer des blessures. de surfaces inflammables.
 Tenir à distance les produits inflammables de
 Ne pas approcher les mains des ventilateurs, cour- l’échappement.
roies et autres pièces en mouvement.
 Maintenir fermés et fixement en place les portes, LES ÉTINCELLES À L’ÉCHAPPEMENT
panneaux, recouvrements et dispositifs de peuvent provoquer un incendie.
protection.
 Arrêter le moteur avant d’installer ou brancher l’appareil.  Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
 Demander seulement à un personnel qualifié d’enlever les dispositifs de
 Utiliser uniquement un pare-étincelles approuvé −
sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’en-
voir codes en vigueur.
tretien et de dépannage.

2-4. Dangers liés à l’air comprimé

RESPIRER L’AIR COMPRIMÉ peut pro- Le METAL CHAUD lors du coupage et
voquer des blessures graves ou causer gougeage plasma peut provoquer un in-
la mort. cendie ou une explosion.
 Ne pas utiliser l’air comprimé pour respirer.  Ne pas couper ou gouger à proximité de produits
 Utiliser l’air comprimé seulement pour le coupa- inflammables.
ge, gougeage et les outils pneumatiques.  Surveillez et garder un extincteur à proximité.

L’AIR COMPRIMÉ peut provoquer DES PIECES CHAUDES peuvent provo-

des blessures. quer des brûlures et blessures.
 Porter des lunettes de sécurité approuvées.
 Ne pas diriger le jet d’air vers d’autres ou soi−  Ne pas toucher le compresseur ou d’autres élé-
même. ments du circuit air comprimé chauds.
 Laisser l’ensemble se refroidir avant de toucher
L’AIR COMPRIME EMMAGASINE ET DES ou d’effectuer la maintenance.
TUYAUX SOUS PRESSION peuvent provo-
quer des blessures. LIRE LES INSTRUCTIONS.
 Relâcher la pression d’air de l’outillage ou du sys-
tème avant d’effectuer la maintenance, avant de  Lisez le manuel d’instructions avant l’utilisation
changer ou de rajouter des éléments ou avant ou la maintenance de l’appareil.
d’ouvrir la purge ou le bouchon de remplissage  Arrêter le moteur et relâcher la pression avant
d’huile. d’effectuer la maintenance.

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

maintenance
 Utiliser un équipement de levage de capacité suffisante pour lever
LA CHUTE DE L’APPAREIL peut l’appareil.
blesser.  En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
 Utiliser l’anneau de levage uniquement pour soulever opposé de l’appareil.
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.

Revenez à la table des matières OM-497 Page 7

 LE SURCHAUFFEMENT peut endom- LIRE LES INSTRUCTIONS.
mager le moteur électrique.
 Utiliser seulement les pièces de rechange d’origine.
 Arrêter ou déconnecter l’équipement avant de dé-  Effectuer la maintenance du moteur et du compres-
marrer ou d’arrêter le moteur. seur (si applicable) suivant ce manuel et le manuel du
moteur/compresseur (si applicable).
 Ne pas laisser tourner le moteur trop lentement sous
risque d’endommager le moteur électrique à cause
d’une tension et d’une fréquence trop faibles.
 Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a LE RAYONNEMENT HAUTE FRÉ-
lieu. QUENCE (H.F.) risque de provoquer
LES ÉTINCELLES VOLANTES ris- des interférences.
quent de provoquer des blessures.  Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements
 Porter un écran facial pour protéger le visage et les de radio−navigation et de communication, les
yeux. services de sécurité et les ordinateurs.
 Demander seulement à des personnes qualifiées familiarisées avec des
 Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de pro- équipements électroniques de faire fonctionner l’installation.
tecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque
 L’utilisateur est tenu de faire corriger rapidement par un électricien quali-
l’on porte l’équipement homologué de protection du visage, des mains et
fié les interférences résultant de l’installation.
du corps.
 Si le FCC signale des interférences, arrêter immédiatement l’appareil.
 Les étincelles risquent de causer un incendie − éloigner toute substance
inflammable.  Effectuer régulièrement le contrôle et l’entretien de l’installation.
 Maintenir soigneusement fermés les portes et les panneaux des sources
L’EMPLOI EXCESSIF peut de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et et un blindage pour réduire les interférences
SURCHAUFFER L’ÉQUIPEMENT. éventuelles.
 Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
 Réduire le courant ou le facteur de marche avant de LE SOUDAGE À L’ARC risque de
poursuivre le soudage.
provoquer des interférences.
 Ne pas obstruer les passages d’air du poste.
 L’énergie électromagnétique risque de provoquer
LES CHARGES ÉLECTROSTATI- des interférences pour l’équipement électronique
QUES peuvent endommager les sensible tel que les ordinateurs et l’équipement com-
circuits imprimés. mandé par ordinateur tel que les robots.
 Veiller à ce que tout l’équipement de la zone de soudage soit compatible
 Établir la connexion avec la barrette de terre avant de électromagnétiquement.
manipuler des cartes ou des pièces.  Pour réduire la possibilité d’interférence, maintenir les câbles de souda-
ge aussi courts que possible, les grouper, et les poser aussi bas que pos-
 Utiliser des pochettes et des boîtes antistatiques
sible (ex. par terre).
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.  Veiller à souder à une distance de 100 mètres de tout équipement élec-
tronique sensible.
UNE REMORQUE QUI BASCULE peut  Veiller à ce que ce poste de soudage soit posé et mis à la terre conformé-
entraîner des blessures. ment à ce mode d’emploi.
 En cas d’interférences après avoir pris les mesures précédentes, il in-
 Utiliser les supports de la remorque ou des blocs combe à l’utilisateur de prendre des mesures supplémentaires telles que
pour soutenir le poids. le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil-
 Installer convenablement le poste sur la remorque tres de ligne ou la pose de protecteurs dans la zone de travail.
comme indiqué dans le manuel s’y rapportant.

2-6. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à To-
l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (télé- ronto : (416) 747−4044, site Web : www.csa−international.org).
phone : (305) 443−9353, site Web : www.aws.org). Practice For Occupational And Educational Eye And Face Protection,
Recommended Safe Practices for the Preparation for Welding and Cutting norme ANSI Z87.1, de l’American National Standards Institute, 11 West
of Containers and Piping, norme American Welding Society AWS F4.1, de 42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site
l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (télé- Web : www.ansi.org).
phone : (305) 443−9353, site Web : www.aws.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,
National Electrical Code, norme NFPA 70, de la National Fire Protection As- norme NFPA 51B, de la National Fire Protection Association, P.O. Box
sociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
(téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org). 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de OSHA, Occupational Safety and Health Standards for General Industry,
la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web : Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent
www.cganet.com). of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Cana- régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
dian Standards Association, Standards Sales, 178 boulevard Rexdale, Web : www.osha.gov).

2-7. Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnétiques Afin de réduire les champs électromagnétiques en milieu de travail, respec-
basse fréquence sur l’organisme ter les consignes suivantes :
En parcourant les câbles de soudage, le courant crée des champs électro- 1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
magnétiques. Les effets potentiels de tels champs restent préoccupants. ruban adhésif.
Cependant, après avoir examiné plus de 500 études qui ont été faites pen- 2. Mettre tous les câbles du côté opposé à l’opérateur.
dant une période de recherche de 17 ans, un comité de spécialistes du 3. Ne pas s’enrouler les câbles autour du corps.
National Research Council a conclu : « L’accumulation de preuves n’a pas 4. Garder le poste de soudage et les câbles le plus loin possible de soi.
démontré que l’exposition aux champs magnétiques et aux champs électri- 5. Placer la pince de masse le plus près possible de la zone de soudage.
ques à haute fréquence constitue un risque pour la santé humaine ». Consignes relatives aux stimulateurs cardiaques :
Toutefois, les études et l’examen des preuves se poursuivent. En attendant Les personnes qui portent un stimulateur cardiaque doivent avant tout
les conclusions finales de la recherche, il serait souhaitable de réduire l’ex- consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-
position aux champs électromagnétiques pendant le soudage ou le mandé de respecter les consignes ci-dessus.
coupage.

OM-497 Page 8 Revenez à la table des matières

 SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions (For Wordless Labels)

Warning! Watch Out! There are

possible hazards as shown by the
symbols.

Become trained and read the

instructions before working on the
machine or welding.
1 Electric shock from welding
electrode or wiring can kill.
1.1 Wear dry insulating gloves. Do
not touch electrode with bare
hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Do not work on unit if engine
is running. Stop engine first.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Do not weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding helmet
with correct shade of filter.
Wear complete body
protection.
5 Do not remove or paint over
(cover) the label.
6 Engine fuel plus flames or
sparks can cause fire.
6.1 Do not smoke while fueling or if
near fuel.
6.2 Stop engine before fueling.
6.3 Do not fuel a hot engine.
7 Engine exhaust gases can kill.
7.1 Vent exhaust outside.
7.2 Use unit outside.

3/96

Return To Table Of Contents OM-497 Page 9

 1 2 3 4 5 6 1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Do not smoke and keep
matches and flames away from
battery.
3 Sparks can cause battery
10 gases to explode. Battery
explosion can blind and injure.
Wear a face shield.
4 1
+ − 4 4 Battery acid can burn skin. Do
1 not spill acid.
11 + − 5 Read Owner’s Manual.
+ − 6 Wear rubber gloves.
7 Dead battery
8 Engine block
3 2 9 Fully charged battery
2 3
10 Do not connect last negative
7 cable to dead battery − connect
+ − + − instead to engine block.
11 Jumper cables − observe
polarity and make connections
S-176 108
in numbered sequence shown.
12 Once dead battery is charged,
disconnect cables in sequence
8 9 12 shown. 3/96

1 1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.
2 2 Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
injury. Keep away from moving
parts.

S-176 106 3/96

Starting Aid Switch. Below 32°F (0°C),

push switch up for 60 seconds before
starting engine.
Starting Instructions:
1 Press and hold Magnetic
Shutdown switch.
2 Turn Engine Control switch to
Start position.
3 Release Engine Control switch
and Starting Aid switch (if used)
when engine starts.
4 Continue holding Magnetic
Shutdown switch for 3 seconds
after engine starts.

OM-497 Page 10 Return To Table Of Contents

1 1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Hot muffler and exhaust pipes
can cause severe burns. Do
not touch hot muffler or pipes.

S-176 230
3/96

1 1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.
2 3 2 Engine fuel plus flames or
sparks can cause fire.
3 Do not smoke while fueling or if
near fuel.
4 Stop engine before fueling.
4 5 Do not fuel a hot engine.
5
6 Use Diesel Fuel only.

3/96

1
1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Falling equipment can cause
serious injury and damage.
3 Use lifting eye to lift or move
unit only. Use proper
equipment when lifting.
4 Do not use lifting eye to lift and
support unit and trailer or other
heavy devices or accessories.

S-176 104

2 3 4 3/96

Return To Table Of Contents OM-497 Page 11

 1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
1 2
2 Fire hazard from leaking
engine fuel. Fire can result from
welding on base at
non-designated areas causing
a possible fuel leak.
3 Fuel tank is located inside
base.
4 Do not weld on base of unit.
5 Weld only on supplied brackets
or bolt unit down.

3 4

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.
1 2 Electric shock from wiring can
kill.
3 Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
2 injury. Keep away from moving
parts.

OM-497 Page 12 Return To Table Of Contents

 1 Remove unit from shipping
S-177 571
crate. Remove Owner’s
1 Manual from unit. Follow
+ 2
instructions to install muffler.
Read Owner’s Manual. Read
labels on unit.
2 3 Use Diesel Fuel only, and fill

+ 4
fuel tank. Leave room for
expansion.
Warning! Watch Out! There
are possible hazards as
3 shown by the symbols. Read
DIESEL Owner’s Manual. Follow
instructions to activate
battery.
4 5 Check oil level. Add oil if
necessary.
6 During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
5 7 After the first 50 hours of
operation, change the oil and
oil filter.
0 − 50 h Std. 200A 0 − 200A

50 h Std.

API CD-MIL L 2104D,

CD/SE, CD/SF
3/96

3-2. Manufacturer’s Rating Labels

CC Models CC/CV Models

Return To Table Of Contents OM-497 Page 13

3-3. Symbols And Definitions

Fast (Run, Weld/

Stop Engine Slow (Idle) Start Engine
Power)

Engine Oil
Starting Aid Battery (Engine) Engine Oil
Pressure

Check Injectors/ Check Valve Protective Earth

Fuel
Pump Clearance (Ground)

Certified/Trained
Positive Negative Welding Arc
Mechanic

A Amperes
V Volts Panel/Local Remote

Air Temperature Or
Alternating
Engine Engine Output
Current
Temperature

Stick (SMAW) Constant Current MIG (GMAW)

TIG (GTAW)
Welding (CC) Welding

Time
h
Hours
s
Seconds
1 Single Phase

Read Operator’s Do Not Switch

3 Three Phase
Manual
Circuit Breaker
While Welding

Engine-Driven,
Electrode
Connection
Work Connection G
Three-Phase
Alternator With
Rectifier
Hz Hertz

X Duty Cycle U0 Rated No Load

Voltage (Average) U2 Conventional
Load Voltage
n
Rated Load
Speed

n1 Rated Idle
Speed n0 Rated No Load
Speed I Current I2 Rated Welding
Current

Contactor On

OM-497 Page 14 Return To Table Of Contents

 SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Maximum
Welding Weld Output Rated Welding Open- Generator Power Fuel
Engine
Mode Range Output Circuit Rating Capacity
Voltage
Standard:
45 − 500 A Single-Phase,
(CC Models) 95 4 kVA/kW, 34/17 A,
CC/DC
15 − 500 A 300 A, 40 Volts DC, 120/240 V AC,
(CC/CV Models) 100% Duty Cycle 50/60 Hz
400 A, 40 Volts DC, Three-Phase Generator DEUTZ 25 gal
60% Duty Cycle Option:* Deutz F3L2011 (95 L)
CV/DC 500 A, 30 Volts DC, Single-Phase/Three-Phase, Air/Oil-Cooled, Three
40% Duty Cycle 12/15 kVA/kW, 50/36A, Cylinder, 33 HP Diesel
(CC/CV 14 − 40 V 56 120/240 VAC, 60 Hz Engine
Models
Only) *In Addition To Standard
4 kVA/kW Generator Power

4-2. Dimensions, Weights, And Operating Angles

Dimensions
60 in (1524 mm) G
Height
(to top of muffler)

28-1/2 in (724 mm)

(mtg. brackets turned in)  Do not exceed tilt angles or engine could
Width be damaged or unit could tip.
30-3/4 in (781 mm)
(mtg. brackets turned out)  Do not move or operate unit where it could
tip.
Depth 65-1/8 in (1654 mm)
A 65-1/8 in (1654 mm)
B* 56 in (1422 mm) A
C* 46-1/2 in (1181) B C

D* 9-5/8 in (244 mm)

E 27-1/2 in (699 mm)
30°
F 1 in (25 mm) H
30°
G 29-1/2 in (749 mm) 20°
9/16 in (14 mm) Dia. D 20°
H Front Panel End
4 Holes

* With mounting brackets in center

position. Dimensions vary with F
location of mounting brackets. E

Weight
w/ Deutz No fuel: 1600 lb (726 kg) 802 161-A
F3L2011 w/fuel: 1775 lb (805 kg)

Return To Table Of Contents OM-497 Page 15

4-3. Volt-Ampere Curves For CC Models
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.

100
Ranges
80 210 − Max
165 − 350
100 − 250
60 65 − 120
DC VOLTS

45 − 85

40

20

0
0 100 200 300 400 500 600 700

DC AMPERES

202 666-A

OM-497 Page 16 Return To Table Of Contents

4-4. Volt-Ampere Curves For CC/CV Models
A. Stick Mode The volt-ampere curves show the
minimum and maximum voltage
100 and amperage output capabilities of
the welding generator. Curves of all
Ranges other settings fall between the
curves shown.
80 Max
150 − 420
110 − 315
DC VOLTS

60 75 − 200
40 − 90

40

20

0
0 100 200 300 400 500 600 700 800 900
DC AMPERES
B. MIG Mode

100

80
DC VOLTS

60

MAX
40

20 MIN

0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
C. TIG Mode

100
90 Ranges
80 50 − 335
40 − 240
70 25 − 150
15 − 75
DC VOLTS

60
50
40
30
20
10
0
0 50 100 150 200 250 300 350 400 450 500
DC AMPERES 202 655 / 202 656 / 202 654

Return To Table Of Contents OM-497 Page 17

4-5. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.

2.00

1.75

1.50
US Gal./Hr.

1.25

1.00

0.75

0.50

0.25 IDLE

0.00
0 50 100 150 200 250 300 350 400
DC WELD AMPERES AT 100% DUTY CYCLE

199 032

4-6. Duty Cycle And Overheating

100% Duty Cycle At 300 Amperes Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
 Exceeding duty cycle can
damage unit and void
warranty.

Continuous Welding
WELD AMPERES

% DUTY CYCLE
199 140

OM-497 Page 18 Return To Table Of Contents

4-7. Standard AC Generator Power Curve
The ac power curve shows the aux-
150 300 iliary power in amperes available at
the 120 and 240 volt receptacles.

125 250
AC VOLTS

100 200

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 193 018

4-8. Optional Three-Phase Generator Curves

The ac power curves show the gen-
A. 12 kVA/kW Single-Phase AC Output (No Weld Load) erator power available in amperes
at the single-phase 120/240 volt re-
280 ceptacle or three-phase 240 volt
terminals.

260
AC VOLTS

240

220

200

180
0 20 40 60 80 100
AC AMPERES
B. 15 kVA/kW Three-Phase AC Output (No Weld Load)
280

260

240
AC VOLTS

220

200

180
0 10 20 30 40 50 60 70
AC AMPERES 198 868 / 198 869

Return To Table Of Contents OM-497 Page 19

 SECTION 5 − INSTALLATION
5-1. Installing Welding Generator (See Sections 5-2 And 5-3)
 Always securely fasten weld-
ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
Movement ble codes.
 Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
 If unit does not have GFCI re-
ceptacles, use GFCI-protected
OR OR extension cord.

 See Section 5-3 for mounting in-

formation.
Grounding:
1 Equipment Grounding Terminal
Location (On Front Panel)
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger insu-
OR OR lated copper wire.

Grounding
1
GND/PE 2

Electrically bond generator frame to

vehicle frame by metal-to-metal contact.

3  Bed liners, shipping skids, and some running

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

Airflow Clearance

18 in
(460 mm)
18 in
18 in (460 mm)
(460 mm)

18 in
18 in (460 mm)
(460 mm)

install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274

OM-497 Page 20 Return To Table Of Contents

5-2. Using Lifting Eye
1 Lifting Eye
2 Nut
1 3 Carriage Bolt
Raise lifting eye until it snaps in
place. Lower lifting eye when not
needed.
To lock the lifting eye in the upright
position, insert a 3/8-16 x 1-1/2 in
2 carriage bolt through slot in bracket
and secure with nut (bolt and nut not
supplied).

Tools Needed:
3

802 311

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

Return To Table Of Contents OM-497 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
brackets or bolt unit down.
Supporting The Unit
 Do not mount unit by sup-
porting the base only at the
four mounting brackets.
Use cross-supports to ade-
2 quately support unit and pre-
vent damage to base.
Mounting Surface:
1 Cross-Supports
OR 2 Mounting Brackets (Supplied)
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
Inadequate support. (Minimum − Not Supplied)
4 3/8-16 x 1 in Screws
(Supplied)
 Do not use flexible mounts. 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.
Using Mounting Brackets Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at
2 the four mounting brackets.

Welding Unit In Place

Bolting Unit In Place
3
2

Tools Needed:
9/16 in install3 6/03 803 274 / 190 250-A / 803 231

OM-497 Page 22 Return To Table Of Contents

5-4. 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 Ref. 802 169-E / Ref. 201 841

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

Return To Table Of Contents OM-497 Page 23

5-5. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1 Eye Protection − Safety
Glasses Or Face Shield
2 Rubber Gloves
5 3 Vent Caps
4 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
4 5 Well
1 Fill each cell with electrolyte to
3 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.
6 Battery Charger
 Read and follow all instruc-
2 tions supplied with battery
charger.
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am-
peres. Disconnect charging cables
and install battery.

 When electrolyte is low, add

only distilled water to cells to
maintain proper level.

5 A For 30 Minutes Tools Needed:

OR

+
− rubber gloves

30 A For 12 Minutes

glasses
drybatt1 1/98 − 0886

OM-497 Page 24 Return To Table Of Contents

5-6. Connecting The Battery
 Reinstall cover after connecting battery.

 Connect Negative (−) Cable Last.

Tools Needed:
1/2 in 802 168-B / Ref. 201 841 / 802 313 / S-0756-C

Notes

Return To Table Of Contents OM-497 Page 25

5-7. Engine Prestart Checks

Full

Diesel

Full

 Check all engine fluids daily. Fuel Oil 802 489-D

 Do not use gasoline. Gasoline will After fueling, check oil with unit on level sur-
Engine must be cold and on a level surface. damage engine. face. If oil is not up to full mark on dipstick,
Unit is shipped with 20W break-in oil. add oil (see maintenance label).
Add fresh diesel fuel before starting to pre-
Automatic shutdown system stops engine if vent air from entering the fuel system (see  To improve cold weather starting:
oil pressure is too low or coolant tempera- engine maintenance label for fuel specifica- Use optional Starting Aid switch (see
ture is too high. tions). Leave filler neck empty to allow room Section 6-1).
for expansion.
 This unit has a low oil pressure shut- Do not run out of fuel or air may enter fuel
Keep battery in good condition. Store
down switch. However, some condi- battery in warm area.
system and cause starting problems. See
tions may cause engine damage before engine manual to bleed air from fuel system.
the engine shuts down. Check oil level Use fuel formulated for cold weather
often and do not use the oil pressure (diesel fuel can gel in cold weather).
shutdown system to monitor oil level. Contact local fuel supplier for fuel in-
formation.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust Use correct grade oil for cold weather
pipe during run-in, see Section 11. (see Section 9-1).

OM-497 Page 26 Return To Table Of Contents

5-8. Connecting To Weld Output Terminals
 Stop engine.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
Stick and TIG Welding
For Stick and TIG welding Direct Current Elec-
trode Positive (DCEP), connect electrode holder
cable to Positive (+) terminal on left and work
cable to Negative (−) terminal on right.
For Direct Current Electrode Negative (DCEN),
reverse cable connections.
If equipped with optional Polarity switch or option-
al Polarity/AC switch, connect electrode holder
cable to Electrode (+) terminal on left and work
cable to Work (−) terminal on right.
MIG and FCAW Welding
For MIG and FCAW welding Direct Current Elec-
trode Positive (DCEP) on CC/CV models, con-
nect wire feeder cable to Positive (+) terminal on
left and work cable to Negative (−) terminal on
right. Use Process/Contactor switch to select
type of weld output (see Section 7-3).
1 For Direct Current Electrode Negative (DCEN),
reverse cable connections.
If equipped with optional Polarity switch or option-
al Polarity/AC switch, connect wire feeder cable
Tools Needed:
2 to Electrode (+) terminal on left and work cable
to Work (−) terminal on right.
802 311 3/4 in

5-9. Selecting Weld Cable Sizes*

Weld Cable Size** and 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)
Weld Output
Terminals
 Stop engine before 10 − 60% 60 − 100%
connecting to weld out- Welding
Duty Duty 10 − 100% Duty Cycle
put terminals. Amperes
Cycle Cycle
 Do not use worn, dam-
aged, undersized, or
poorly spliced cables.

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)

* Thischart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-E−

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
Return To Table Of Contents OM-497 Page 27
5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models
1 Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
RC13 (see Section 6-3).

Ref. 154 862-A / 048 720-K / 802 311-A

Notes
MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)

22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

OM-497 Page 28 Return To Table Of Contents

5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models

Socket* Socket Information

A 24 volts ac. Protected by circuit

breaker CB5.
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.

New! LDR-14 long D Remote control circuit common.

REMOTE
distance remote OUTPUT
(includes 120 V CONTROL
receptacle) 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

I ac. Protected by circuit breaker
OR CB6.
115 VOLTS AC

Contact closure to I completes

J 115 volt ac contactor control
circuit.

K Chassis common.
802 311
GND

NEUTRAL G Circuit common for 24 and 115

volt ac circuit.

*The remaining sockets are not used.

Notes

Start Your Professional 400 Trade Square East, Troy, Ohio 45373
Over 80,000 trained
Welding Career Now! 1-800-332-9448 www.welding.org since 1930!
Return To Table Of Contents OM-497 Page 29
SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS

6-1. Front Panel Controls For CC Models (See Section 6-2)

5 6

13 14 18 19 10 11 12 4 7

3 1
15 16

17

201 841 / 802 311-A

OM-497 Page 30 Return To Table Of Contents

6-2. Description Of Front Panel Controls For CC Models (See Section 6-1)

Engine Starting Controls 5 Engine Temperature Light 13 Ampere Range Switch

Light goes on and engine stops if engine oil
 Do not switch under load.
1 Magnetic Shutdown Switch temperature is above 266 ° F (130° C).
 Stop engine and fix trouble if Engine Use switch to select weld amperage range.
Use switch during start-up to bypass engine For most welding applications, use lowest
Temperature light goes on.
shutdown system. System stops engine if oil amperage range possible to help prevent arc
pressure is too low or engine temperature is 6 Engine Oil Pressure Light
outages.
too high. Light goes on and engine stops if oil pressure
is below 22 psi (150 kPa). Light goes on mo- 14 Amperage Adjust Control
2 Starting Aid Switch (Optional) mentarily during start-up but goes out when
engine reaches normal oil pressure. Control adjusts amperage within range se-
Use switch to energize glow plug starting aid lected by Ampere Range switch. Weld output
for cold weather starting.  Stop engine and fix trouble if Engine would be about 153 A DC with controls set as
Oil Pressure light stays on after start- shown (50% of 100 to 205 A).
Push switch up for 60 seconds to operate the up.
glow plug before cranking engine (see start- 7 Fuel Light  The numbers around the control are for
ing instructions following). Fuel light is not active on this model. reference only and do not represent an
8 Engine Hour Meter actual percentage value.
3 Engine Control Switch
Engine Gauges 15 Stick/TIG Selection Switch
Use switch to start engine, select engine
speed (if unit has auto idle option), and stop
 To read gauges and engine indicator Use switch to disable the max OCV circuit
lights with engine off, turn Engine Control and the arc drive (dig) circuit for scratch start
engine. TIG welding (see max OCV note under Weld
switch to Run/Idle and press Magnetic
Shutdown switch (see Section 9-8). Controls).
In Run position, engine runs at weld/power
speed. In Run/Idle position (optional), engine 9 Fuel Gauge When switch is in the Stick position, the max
runs at idle speed at no load and weld speed Use gauge to check fuel level. OCV circuit resets Amperage Adjust Control
with load applied. R1 to maximum when the arc breaks.
To check fuel level when engine is not run-
ning, turn Engine Control switch to Run/Idle Also in the Stick position, the arc drive (dig)
To Start: position and press Magnetic Shutdown circuit provides additional amperage during
switch. low voltage (short arc length conditions) to
 If engine does not start, let engine come 10 Battery Voltmeter (Optional) prevent “sticking” electrodes.
to a complete stop before attempting re-
Use gauge to check battery voltage and moni- When switch is in Scratch Start TIG position,
start.
tor the engine charging system. The meter the max OCV and arc drive (dig) circuits are
should read about 14 volts dc when the en- disabled and OCV changes when the control
Above 32
F (0
C): turn Engine Control
gine is running, and about 12 volts dc when is adjusted.
switch to Start while pressing Shutdown
the engine is stopped.
switch. Release Engine Control switch when
11 Engine Temperature Gauge (Optional) 16 Amperage Adjust Switch And Remote
engine starts. Continue holding Shutdown
Amperage Adjust Receptacle
switch until engine indicator lights go out. Normal temperature is 212 - 239° F (100 -
115° C). When equipped with gauge option, Connect optional remote control to RC13
Below 32
F (0
C) using optional starting engine stops if temperature exceeds 270° F (See Section 5-10). Use switch to select front
aid switch: (132° C). panel or remote amperage control. For re-
12 Engine Oil Pressure Gauge (Optional) mote control, place switch in Remote position
Turn Engine Control switch to Run/Idle posi- and connect remote control to Remote Am-
tion. Push Starting Aid switch up for 60 sec- Normal pressure is 30 − 60 psi (206 − 414 perage Adjust receptacle RC13 (see Sec-
onds. While still holding Starting Aid switch, kPa). When equipped with gauge option, en- tions 5-10 and 6-3).
press Magnetic Shutdown switch and turn gine stops if pressure is below 20 psi (138
Engine Control switch to Start. Release En- kPa). 17 Polarity Switch (Optional)
gine Control switch and Starting Aid switch Weld Controls
when engine starts. Continue holding Shut-  Do not switch under load.
down switch until engine indicator lights go  Max OCV Control Circuit: This unit has Use switch to change weld output. Select ei-
out. a max OCV control circuit that resets Am- ther DC Electrode Positive (DCEP) or DC
perage Adjust control R1 to maximum Electrode Negative (DCEN).
To Stop: turn Engine Control switch to Off when the arc breaks. When an arc is
position. struck, weld output control returns to the Weld Meters
R1 front panel or combination front panel/
Engine Indicator Lights remote control setting. The Amperage 18 DC Voltmeter (Optional)
Adjust control adjusts amperage only
when welding and does not adjust open- Voltmeter displays voltage at the weld output
4 Battery Charging Light
circuit voltage. terminals, but not necessarily the welding arc
Light goes on if engine alternator is not charg- due to resistance of cable and connections.
ing battery. Engine continues to run. The max OCV circuit is disabled when 19 DC Ammeter (Optional)
the Stick/TIG Selection switch is in
 Stop engine and fix trouble if Battery Scratch Start TIG position (see item 15). Ammeter displays amperage output of the
Charging light goes on. unit.

Return To Table Of Contents OM-497 Page 31

6-3. Remote Amperage Control On CC Models (Optional)
1 Remote Amperage Adjust
Receptacle RC13
1
Connect optional remote control to
RC13 (see Section 5-10).

In Example:
Example: Combination Remote Amperage Control (Stick) Range = 100 to 205 A DC
Percentage Of Range = 50%
Max = About 153 A DC (50% of 100 to 205)

Max (153 A DC)

Min (75 A DC)

Set Switches Set Range Set Control Adjust Optional Remote Control
0774 / Ref. 154 862-A / Ref. 181 711-A / 802 311

6-4. Weld Control/Arc Condition Information Label

 Set weld controls as shown to
achieve softer or stiffer arc condi-
tions for different applications.

212 944-A

OM-497 Page 32 Return To Table Of Contents

Notes

Return To Table Of Contents OM-497 Page 33

 SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS

7-1. Front Panel Controls For CC/CV Models (See Section 7-2)
5 6

14 15 19 20 10 11 12 4 7

13 16 3 1

18 17

OR

201 579 / 802 311-D

OM-497 Page 34 Return To Table Of Contents

7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)

Engine Starting Controls 6 Engine Oil Pressure Light 15 Voltage/Amperage Adjust Control
1 Magnetic Shutdown Switch Light goes on and engine stops if oil pressure With Process/Contactor switch in any Stick or
is below 22 psi (150 kPa). Light goes on mo- TIG setting, use control to adjust amperage
Use switch during start-up to bypass engine mentarily during start-up but goes out when within range selected by Ampere Range
shutdown system. System stops engine if oil engine reaches normal oil pressure. switch. With Process/Contactor switch in any
pressure is too low or engine temperature is MIG position, use control to adjust voltage.
too high.  Stop engine and fix trouble if Engine
Oil Pressure light stays on after start- With Voltage/Amperage Adjust Switch in Re-
2 Starting Aid Switch (Optional) up. mote position, control limits the remote am-
perage in TIG mode, but has no effect in Stick
Use switch to energize the glow plug starting 7 Fuel Light and MIG modes.
aid for cold weather starting. Fuel light is not active on this model. Weld output would be about 213 A DC with
Push switch up for 60 seconds to operate the 8 Engine Hour Meter controls set as shown (50% of 110 to 315 A).
glow plug before cranking engine (see start-
ing instructions following).
Engine Gauges  The numbers around the control are for
reference only and do not represent an
3 Engine Control Switch  To read gauges and engine indicator actual percentage value.
lights with engine off, turn Engine Control
Use switch to start engine, select engine switch to Run/Idle and press Magnetic 16 Voltage/Amperage Adjust Switch And
speed (if unit has auto idle option), and stop Shutdown switch (see Section 9-8). Remote 14 Receptacle
engine. Use switch to select front panel or remote
9 Fuel Gauge
In Run position, engine runs at weld/power voltage/amperage control. For remote con-
Use gauge to check fuel level. trol, place switch in Remote position and con-
speed. In Run/Idle position (optional), engine
runs at idle speed at no load and weld speed To check fuel level when engine is not run- nect remote control to Remote 14 receptacle
with load applied. ning, turn Engine Control switch to Run/Idle RC14 (see Sections 5-11 and 7-4).
position and press Magnetic Shutdown 17 Polarity Switch (Optional)
To Start: switch.
 Do not switch under load.
 If engine does not start, let engine come 10 Battery Voltmeter (Optional)
Use switch to change weld output. Select ei-
to a complete stop before attempting re- Use gauge to check battery voltage and moni- ther DC Electrode Positive (DCEP) or DC
start. tor the engine charging system. The meter Electrode Negative (DCEN).
should read about 14 volts dc when the en-
Above 32
F (0
C): turn Engine Control gine is running, and about 12 volts dc when 18 Polarity/AC Switch (Optional)
switch to Start while pressing Shutdown the engine is stopped.  Electric shock can kill.
switch. Release Engine Control switch when
engine starts. Continue holding Shutdown 11 Engine Temperature Gauge (Optional)  Do not use AC output in damp areas,
switch until engine indicator lights go out. Normal temperature is 212 - 239° F (100 - if movement is confined, or if there is
a danger of falling.
Below 32
F (0
C) using optional starting 115° C). When equipped with gauge option,
aid switch: engine stops if temperature exceeds 270° F  Use AC output ONLY if required for the
Turn Engine Control switch to Run/Idle posi- (132° C). welding process. If AC output is re-
tion. Push Starting Aid switch up for 60 sec- quired, use remote output control if
12 Engine Oil Pressure Gauge (Optional)
onds. While still holding Starting Aid switch, present on unit.
press Magnetic Shutdown switch and turn Normal pressure is 30 − 60 psi (206 − 414
 Do not switch under load.
Engine Control switch to Start. Release En- kPa). When equipped with gauge option, en-
gine Control switch and Starting Aid switch gine stops if pressure is below 20 psi (138 Use Polarity/AC switch to select AC or DC
when engine starts. Continue holding Shut- kPa). weld output and DC weld output polarity. For
down switch until engine indicator lights go Direct Current Electrode Negative (DCEN),
Weld Controls
out. turn switch to − (Negative) position. For Direct
13 Process/Contactor Switch Current Electrode Positive (DCEP), turn
To Stop: turn Engine Control switch to Off See Section 7-3 for Process/Contactor switch to + (Positive) position. For weld pro-
position. switch information. cesses that require alternating current (AC),
use AC position.
Engine Indicator Lights 14 Ampere Range Switch
Weld Meters
4 Battery Charging Light  Do not switch under load.
Light goes on if engine alternator is not charg- Use switch to select weld amperage range.
 Optional weld meters do not work with
ing battery. Engine continues to run. optional Polarity/AC switch in AC
Use the lowest four ranges for Stick and TIG position.
 Stop engine and fix trouble if Battery welding. Read the upper set of numbers at
19 DC Voltmeter (Optional)
Charging light goes on. each range for Stick welding and the lower set
at each range for TIG welding. Voltmeter displays voltage at the weld output
5 Engine Temperature Light terminals, but not necessarily the welding arc
Use the highest range for MIG welding and for
Light goes on and engine stops if engine oil due to resistance of cable and connections.
cutting and gouging (CAC-A).
temperature is above 266 ° F (130° C). 20 DC Ammeter (Optional)
For most welding applications, use lowest
 Stop engine and fix trouble if Engine amperage range possible to help prevent arc Ammeter displays amperage output of the
Temperature light goes on. outages. unit.

Return To Table Of Contents OM-497 Page 35

7-3. Process/Contactor Switch On CC/CV Models
1 Process/Contactor Switch
 Weld output terminals are ener-
gized when Process/Contactor
switch is in an Electrode Hot
position and the engine is
1 running.
 DC voltage is still present at the
weld terminals when Process/
Contactor switch is in the
Remote − 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 7-4).
Place switch in Remote positions to turn
weld output on and off with a device con-
nected to the remote 14 receptacle.
Place switch in Electrode Hot 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 additional
amperage during low voltage (short arc
length conditions) to prevent “sticking”
electrodes.
The arc drive (dig) circuit is disabled
when switch is in MIG or TIG positions.

 Place switch in Electrode Hot -

Stick position when using optional
three-phase generator (see Sec-
tion 8-2).

 The engine auto idle option does

not work in the Remote-TIG mode.

Process/Contactor Switch Settings

Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)

GTAW With HF Unit, Pulsing

Remote − TIG At Remote 14 Receptacle Not Active
Device, Or Remote Control

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

Remote − MIG MIG (GMAW) At Remote 14 Receptacle Active

Electrode Hot − MIG MIG (GMAW) Electrode Hot Active

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

Electrode Hot − Scratch

Scratch Start TIG (GTAW) Electrode Hot Active
Start TIG

OM-497 Page 36 Return To Table Of Contents

7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)
1 Remote 14 Receptacle RC14
Connect optional remote control to
RC14 (see Section 5-11).

Example: Combination Remote Amperage Control (Stick) In Example:

Process = Stick (Using Remote On/Off)
Range = 110 to 315 A DC
Min = 110 A DC
Max = 315 A DC

Max (315 A DC)

Min (110 A DC)

Set V/A Set Remote
Set Range Control Not Adjust Optional Remote Control
Adjust Switch Process
Used In Remote
Stick Mode

Example: Combination Remote Amperage Control (TIG) In Example:

Process = TIG (Using Remote On/Off)
Range = 40 to 240 A DC
Percentage Of Range = 50%
Min = 40 A DC
Max = About 140 A DC (50% of 40 to 240)

Max (140 A DC)

Min (40 A DC)

Set V/A Set Remote
Set Range Set Control Adjust Optional Remote Control
Adjust Switch Process

0774 / Ref. 201 579 / 802 169-E

Return To Table Of Contents OM-497 Page 37

 SECTION 8 − OPERATING AUXILIARY EQUIPMENT

8-1. 120 Volt And 240 Volt Receptacles

1 120 V 20 A AC GFCI
Receptacle GFCI1
2 240 V 30 A AC Twistlock
Receptacle RC1
Receptacles supply 60 Hz single-
phase power at weld/power speed.
If a ground fault is detected, GFCI
Reset button pops out and
1 2 receptacle does not work. Check
for faulty tools plugged in
receptacle. Press button to reset
3 GFCI1.

 At least once a month, run en-

gine at weld/power speed and
press test button to verify GFCI
is working properly.
3 Circuit Breaker CB1
4
4 Circuit Breaker CB2
CB1 protects RC1 and the genera-
tor winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset breaker.
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset breaker.

 If a circuit breaker continues to

open, contact Factory Autho-
rized Service Agent.

 Generator power is not af-

fected by weld output.
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all re-
ceptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW

191 624-A

OM-497 Page 38 Return To Table Of Contents

8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)
 Place Process/Contactor switch
in Electrode Hot - Stick position
when using three-phase genera-
tor (see Section 7-3).
Single-Phase Power Connection 1 2
Single-Phase Generator Power
1 120/240 V 50 A Receptacle
RC5
RC5 is connected to the optional
three-phase generator and supplies
60 Hz single-phase power at weld/
power speed. Maximum output from
RC5 is 12 kVA/kW. Power available
at RC5 is reduced when welding.
2 Circuit Breaker CB7
Circuit breaker CB7 protects single-
phase receptacle RC5 and the load
wires from overload. If CB7 opens, all
generator output stops and the recep-
tacle does not work.
Three-Phase Generator Power
Three-Phase Power Connection Single Three
AC
Phase Phase
 Stop engine.
Output
1 3  Power and weld outputs are
 Close panel opening Volts 120/240 240 live at the same time. Discon-
if no connections are Amps 50 36 nect or insulate unused
made to generator. cables.
KVA/KW 12 15
Frequency 60 Hz  Have qualified person install ac-
Engine Speed 1850 RPM cording to circuit diagram and
Generator Power Guidelines
Lead 42 connects to GROUND stud on (see Section 12).
front of unit.
Jumper 42 is connected to 90 at factory. Remove generator power panel
mounting screws. Tilt panel forward.
93 3 Lead 93

91 4 Lead 92
Remove plug
5 Lead 91
before inserting
leads. Reinstall 90 6 Lead 42 (Circuit Grounding
bushing. Lead)
92 7 Lead 90 (Neutral)
Rear Of Panel 4
8 Isolated Neutral Terminal
5
91 92 93 9 Jumper Lead 42
3
6 10 Grounding Terminal
2 Jumper 42 is connected to lead 90 at
factory. Jumper 42 may be discon-
12 nected from neutral to meet applica-
7 ble electrical codes.
Lead 42 connects to front panel
Ground stud.
10
11 User-Supplied Leads
12 Circuit Breaker CB7 User
11 Terminals
Connect user-supplied leads to ter-
 Close panel minals on CB7 and to the isolated
opening if no neutral terminal and grounding termi-
9 connections nal as necessary.
are made to
power plant.  Circuit breaker CB7 protects
single-phase receptacle RC5
240V
8 and the load wires from overload.
120V 1-Phase If CB7 opens, all generator out-
120V put stops and the receptacle
240V Tools Needed: does not work.
240V 3-Phase Reinstall generator power panel.
240V

Ref. 197 399 / 802 332-E

Return To Table Of Contents OM-497 Page 39

8-3. Optional Generator Power Receptacles
1 120 V 20 A AC GFCI
Receptacle GFCI1
2 240 V 16 A AC European
European Receptacle Receptacle RC1
5 1 2 3 240 V 15 A AC Australian
Receptacle RC1
4 240 V 15 A AC South African
Receptacle RC1
6
Receptacles supply 60 Hz single-
phase power at weld/power speed.
If a ground fault is detected, the
GFCI Reset button pops out and
the receptacle does not work.
Check for faulty tools plugged in
receptacle. Press button to reset
GFCI1.

 At least once a month, run en-

gine at weld/power speed and
press test button to verify GFCI
Australian Receptacle
is working properly.
1 3 5 Circuit Breaker CB2
5
6 Circuit Breaker CB3
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
6 work. Press button to reset breaker.
CB3 protects RC1 from overload. If
CB3 opens, RC1 does not work.
Press button to reset breaker.

 If a circuit breaker continues to

open, contact Factory Autho-
rized Service Agent.

 Generator power is not af-

fected by weld output.
South African Receptacle Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
5 1 4 RC1. Maximum output from all re-
ceptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
6 (240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW

191 624

OM-497 Page 40 Return To Table Of Contents

 SECTION 9 − MAINTENANCE & TROUBLESHOOTING
9-1. Maintenance Label

Return To Table Of Contents OM-497 Page 41

9-2. Routine Maintenance

Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.

 Stop engine before maintaining.

Recycle  See Engine Manual and Maintenance Label for

engine important start-up, service, and storage informa-
fluids. tion. Service engine more often if used in severe
conditions.
* To be done by Factory Authorized Service Agent.

Every 8 h

FUEL Drain Water

Check Fluid
Wipe Up WATER From Fuel
Levels. See
Spills. System. See
Section 5-7.
Section 9-6.

Every 50 h

Clean And
Clean Air Filter.
Tighten Weld
See Section 9-3.
Terminals.

Every 100 h

Clean Clean And

Cooling Tighten
System. Battery
Connections.

Check air cleaner

hoses for cracks
and loose clamps.

Every 250 h

Replace 1/2 in. Check

Unreadable (13 mm) Belt
Labels. Tension.

Check And
Clean Spark
Arrestor. See
Section 9-4.

Every 500 h
Repair Or
Replace
Cracked
Cables.

OM-497 Page 42 Return To Table Of Contents

 Every 1000 h

Change Oil Filter.

Change Oil. See See Section 9-6.
Section 9-6. Service more often
in dirty conditions.

Service Welding
Change Fuel Generator Brushes
Filters. See And Slip Rings.
Section 9-6. Service More Often
In Dirty Conditions.*

Drain Sludge
FUEL Check
From Fuel
Tank. See Valve
SLUDGE
Section 9-6. Clearance.*

Blow Out Or
Vacuum Inside.
OR During Heavy
Service,
Clean Monthly.

Every 3000 h

Clean/Set
Injectors.*

Return To Table Of Contents OM-497 Page 43

9-3. Servicing Air Cleaner
 Stop engine.
 Do not run engine without air
cleaner or with dirty element. En-
1 2 3 4 gine damage caused by using a
damaged element is not covered
by the warranty.

 The air cleaner primary element can

be cleaned but the dirt holding 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
Optional makes cleaning a risk. Consider the
risk of unwarrantable equipment
5
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-
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-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
Keep nozzle 1 Housing
2 in (51 mm)
from element. 2 Safety Element (Optional)
3 Primary Element
4 Dust Cap
5 Dust Ejector
To clean air filter:
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
Blow Inspect
(if present). Reinstall cap.
 Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).

aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 201 841

OM-497 Page 44 Return To Table Of Contents

9-4. Inspecting And Cleaning Optional Spark Arrestor Muffler
 Stop engine and let cool.
1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3 Exhaust Pipe
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
 Stop engine and let cool.
3
Reinstall cleanout plug.
2 1

Tools Needed:
3/8 in
Ref. 802 311 / Ref. 802 160 / Ref. 201 841

Return To Table Of Contents OM-497 Page 45

9-5. Adjusting Engine Speed
 Stop engine and let cool.
Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine no
load speed with a tachometer or fre-
quency meter (see table for no load
speeds). If necessary, adjust speed
as follows:
Start engine and run until warm.
On CC Models, place Stick/TIG
switch in Stick position.
On CC/CV models, turn Process/
Contactor switch to Stick − Elec-
trode Hot position.
Standard Models:
1 Engine Speed Adjustment
1850 rpm Max.
Screw
(61.6 Hz)
1250 rpm 2 Locking Nut
(41.6 Hz) Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
 Do not set engine speed higher
than specified.
Models With Automatic Idle
(Optional)
3 Throttle Rod
4 Locknut
5 Throttle Stop Screw
Standard Models 6 Throttle Lever
Loosen locknuts. Place engine
control switch in Run/Idle position.
Turn throttle rod until engine runs at
idle speed. Tighten locknuts.
2  To prevent solenoid damage,
be sure a 1/8 in (3 mm) gap
exists between the throttle
1
stop screw and throttle lever
when the solenoid is held in
the energized position.
7 Engine Speed Adjustment
Screw
8 Locknut
Place engine control switch in Run
Models With Automatic Idle (Optional) position.
Loosen locknut. Turn screw until
engine runs at weld/power speed.
Tighten locknut.

 Do not set engine speed higher

4 3 than specified.
 Stop engine.
Close door.

5
6
7

8
Tools Needed:

3/8, 7/16 in
Ref. 802 313-C / 802 489

OM-497 Page 46 Return To Table Of Contents

9-6. Servicing Fuel And Lubrication Systems

Tools Needed:

7/16, 11/16 in

1
7

Ref. 800 159-E / Ref. 802 170-A / 802 489-C

 Stop engine and let cool. in base. See engine manual and engine To replace secondary fuel filter:
maintenance label for oil/filter change in-
 After servicing, start engine and formation.
See engine manual.
check for fuel leaks. Stop engine, Close doors.
tighten connections as necessary, To drain water from fuel system: To drain sludge from fuel tank:
and wipe up spilled fuel.
Open primary fuel filter petcock and drain  Beware of fire. Do not smoke and
1 Oil Filter keep sparks and flames away from
water into metal container. Close petcock
2 Oil Drain Valve And Hose when water-free fuel flows. drained fuel. Dispose of drained fuel
3 Oil Fill Cap in an environmentally-safe manner.
To replace primary fuel filter: Do not leave unit unattended while
4 Primary Fuel Filter (Fuel/Water Sepa- draining fuel tank.
rator) Turn filter counterclockwise. Remove filter.  Properly lift unit and secure in a level
5 Petcock position. Use adequate blocks or
Apply thin coat of fuel to gasket on new filter.
stands to support unit while drain-
6 Secondary Fuel Filter Fill filter with fuel. Install filter and turn clock-
ing fuel tank.
wise. Bleed air from fuel system according
7 Fuel Tank Sludge Drain Valve to engine manual. Attach 1/2 ID hose to drain valve. Put metal
To change oil and filter: container under drain, and use screwdriver
Inspect fuel line, and replace if cracked or to open sludge drain valve. Close valve
Route oil drain hose and valve through hole worn. when sludge has drained. Remove hose.
Return To Table Of Contents OM-497 Page 47
9-7. Overload Protection
 Stop engine.

 When a circuit breaker or fuse

opens, it usually indicates a more
serious problem exists. Contact
Factory Authorized Service Agent.
1 Fuse F1
2 Fuse F2
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 gener-
ator power is still available.
3 Circuit Breaker CB4 (Not Shown)
2 1 4 Circuit Breaker CB5
(CC/CV Models Only)
5 Circuit Breaker CB6
(CC/CV Models Only)
6 Circuit Breaker CB10 (Not Shown)
7 Circuit Breaker CB11
9 8 Circuit Breaker CB12
8 9 Circuit Breaker CB13
7
10 Circuit Breaker CB14
(Optional − Not Shown)
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-
4 5 put to field current regulator board PC1
(CC/CV models only). If CB5 opens,
weld output and 24 volt output to RC14
stops. On units with optional three-
phase generator, ac output at recep-
tacle RC5 also stops if CB5 opens.
CB6 protects the 115 volt ac output to
remote receptacle RC14 (CC/CV mod-
els only). 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. On CC models, if CB11 opens the
max OCV circuit does not work and
open circuit voltage is variable at all
times (see max OCV note under Weld
Controls in Section 6-2). If CB11 opens
on CV models, weld output stops (gen-
erator 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.
CB14 protects the throttle solenoid on
units with the auto idle option. If CB14
opens, the engine will not run at idle
speed. CB14 automatically resets when
the fault is corrected.
Press button to reset breaker.
802 170-D / Ref. 802 311

OM-497 Page 48 Return To Table Of Contents

9-8. Diagnosing Causes Of Engine Fault Shutdowns
Use the front panel engine lights to
help determine the cause of an au-
tomatic engine shutdown.

Pre-Start Diagnostic Checks  Correct the cause of the shut-

down before operating the
welding generator.

 This unit does not have a bat-

tery charging fault shutdown.
The engine continues to run if
the Battery Charging Light
goes on.

Turn Engine Control Switch To Run/Idle Normal Condition:

Position While Pressing Magnetic Oil Pressure Light On;
Shutdown Switch. Battery Charging And Temperature Lights Off.
If Oil Pressure Light Is Off, See Factory Authorized Service Agent.
If Battery Charging Light Is On, Have Factory Authorized Service
Agent Check Alternator.
If Temperature Light Is On, Correct Cause Of Overheating
(See Engine Manual).
If Engine Is Okay, See Factory Authorized Service Agent.
If Fault Continues, See Factory Authorized Service Agent.

Diagnostic Checks While Running

20s

Start Engine (With No Load Applied). Continue Pressing Shutdown Switch Normal Condition:
Until Engine Lights Go Off. Engine Lights Go Off As Engine Reaches
Normal Operating Condition.
Lights That Stay On After 20 Sec. Indicate Fault
Condition.
Stop Engine And Correct Fault (See Above) If Fault
Continues, See Factory Authorized Service Agent.

Ref. 201 841

Return To Table Of Contents OM-497 Page 49

9-9. Troubleshooting Tables

A. Welding − CC Models

Trouble Remedy

No weld output; generator power output Check position of Ampere Range switch.
okay at ac receptacles.

Check position of optional Polarity switch.

Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
control to Remote Amperage Adjust receptacle RC13 (see Sections 5-10 and 6-1).

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-10).

Check fuse F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent check inte-
grated rectifier SR2 and the rotor.

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

No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.

Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (see Section 9-7).

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 engine weld/power speed, and adjust if necessary (see Section 9-5).

Have Factory Authorized Service Agent check OCV control circuit.

Low weld output. Check engine weld/power speed, and adjust if necessary (see Section 9-5).

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, 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 9-7).
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. Check engine weld/power speed, and adjust if necessary (see Section 9-5).

Maximum weld output only in each Have Factory Authorized Service Agent check control relay CR7.
ampere range (with Stick/TIG Selection
switch in Stick position).

No remote fine amperage control. Place Amperage Adjust switch in correct position.

Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-10).

Repair or replace remote control device.

Reset circuit breaker CB11 (see Section 9-7). Have Factory Authorized Service Agent check control relay
CR7.

Have Factory Authorized Service Agent check OCV control circuit.

Have Factory Authorized Service Agent check control relay CR7.

OM-497 Page 50 Return To Table Of Contents

B. Welding − CC/CV Models

Trouble Remedy

No weld output; generator power output Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and
okay at ac receptacles. connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-11 and 9-7).

Check position of Ampere Range switch.

Check position of optional Polarity switch or Polarity/AC switch.

Reset circuit breaker CB11 (see Section 9-7).

Reset circuit breaker CB5 (see Section 9-7). Check for faulty remote device connected to RC14.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).

Have Factory Authorized Service Agent check connector board PC6 and connections.

Check fuse F2, and replace if open (see Section 9-7). 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 out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

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.

High weld output. Check position of Ampere Range switch and Voltage/Amperage Adjust control.

Check engine weld/power speed, and adjust if necessary (see Section 9-5).

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 engine weld/power speed, and adjust if necessary (see Section 9-5).

Check fuses F1 and F2, and replace if open (see Section 9-7). Have 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 9-7).
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. Check engine weld/power speed, and adjust if necessary.

No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position.
control.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).

Repair or replace remote control device.

Constant speed wire feeder does not Reset circuit breaker CB5 or CB6 (see Section 9-7).
work.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-11).

Repair or replace wire feeder.

Low CV weld output. Set Ampere Range switch to highest range.

Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.

Repair or replace remote control device.

Have Factory Authorized Service Agent check field current regulator board PC1.

Return To Table Of Contents OM-497 Page 51

C. Standard Generator Power

Trouble Remedy

No generator power output at ac recep- Reset receptacle circuit breakers.

tacles; weld output okay.

No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.

Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, and the rotor.

Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (CC models) or field
current regulator board PC1 (CC/CV models) (see Section 9-7).

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

High output at generator power ac re- Check engine weld/power speed, and adjust if necessary (see Section 9-5).
ceptacles.

Have Factory Authorized Service Agent adjust generator power field current resistor R3.

Low output at generator power ac recep- Check engine weld/power speed, and adjust if necessary (see Section 9-5).
tacles.

Check fuse F1, and replace if open (see Section 9-7). Have Factory Authorized Service Agent check
integrated rectifier SR1, resistor R3, and capacitor C9.

D. Optional Three-Phase Generator Power (CC/CV Models Only)

Trouble Remedy

No or low output at optional three- Place Process/Contactor switch in Electrode Hot - Stick position (see Section 7-3).
phase generator/receptacle RC5.

Reset circuit breaker CB7(see Section 9-7).

Reset circuit breaker CB5 (see Section 9-7).

Check engine weld/power speed, and adjust if necessary (see Section 9-5).

Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
PC1.

High output at optional three-phase Check engine weld/power speed, and adjust if necessary (see Section 9-5).
generator /receptacle RC5.

Have Factory Authorized Service Agent check field current regulator board PC1.

Erratic output at optional three-phase Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
generator/receptacle RC5. PC1.

E. 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 9-7).
Have Factory Authorized Service Agent check engine wiring harness and components.

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check Engine Control switch S1.

Engine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine.

Check fuel level.

Reset circuit breaker CB13 (see Section 9-7). 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.

OM-497 Page 52 Return To Table Of Contents

 Trouble Remedy

Have Factory Authorized Service Agent check control relay CR2, and fuel solenoid FS1.

Air in fuel system. See engine manual.

Engine starts, but stops when Magnetic When starting engine, continue holding Magnetic Shutdown switch until after engine indicator lights go
Shutdown switch is released. out.

Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Sections 5-7 and 9-8).

Engine hard to start in cold weather. Use optional starting aid switch (see Section 6-1 or 7-2).

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 9-1).

Engine suddenly stops. Check fuel level.

Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Sections 5-7 and 9-8).

See engine manual.

Engine slowly stopped and cannot be Check fuel level.

restarted.

Check engine air and fuel filters (see Sections 9-3 and 9-6).

See engine manual.

Battery discharges between uses. Turn Engine Control switch 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 (models with idle option
only).

Check for obstructed throttle solenoid.

Engine does not run at idle speed CC models: place Stick/TIG Selection switch in Stick position.
(models with idle option only). CC/CV models: place Process/Contactor switch in any position but Remote-TIG.

Check for obstructed throttle solenoid.

Allow circuit breaker CB14 to reset. Have Factory Authorized Service Agent check throttle solenoid TS1
and linkage (see Section 9-7).

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.

Return To Table Of Contents OM-497 Page 53

 SECTION 10 − ELECTRICAL DIAGRAMS

Figure 9-1. Circuit Diagram For CC Welding Generator

OM-497 Page 54 Return To Table Of Contents
 215 300-A

Return To Table Of Contents OM-497 Page 55

 Figure 9-2. Circuit Diagram For CC/CV Welding Generator
OM-497 Page 56 Return To Table Of Contents
 215 301-A

Return To Table Of Contents OM-497 Page 57

 SECTION 11 − RUN-IN PROCEDURE
run_in1 8/01

11-1. Wetstacking
 Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
1 Welding Generator
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.

 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
1 run-in.
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for addition-
al engine run-in information.

OM-497 Page 58 Return To Table Of Contents

11-2. Run-In Procedure Using Load Bank
 Stop engine.
 Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
 Keep exhaust and pipe away
4
from flammables.
 Do not perform run-in
2 procedure at less than 20
volts weld output and do not
1 exceed duty cycle or equip-
ment damage may 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
minutes.
3 Set load bank switches and then
adjust generator A/V control so load
equals rated voltage and current of
generator (see nameplate, rating
label, or the specifications 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.

 Check oil level frequently dur-

ing run-in; add oil if needed.
After one hour (minimum) place A/V
control in minimum position, then
turn off load bank to remove load.
Run engine several minutes at no
load.
 Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0683

Return To Table Of Contents OM-497 Page 59

11-3. Run-In Procedure Using Resistance Grid
 Stop engine.
 Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
 Keep exhaust and pipe away
6
from flammables.
 Do not perform run-in
2 procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
1 Resistance Grid
Use grid sized for generator rated
output.
1 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
shown, if not provided on generator.
3 5 Start engine and run for several
minutes.
Set grid switches and then adjust
generator A/V control so load
equals rated voltage and current of
the generator (see nameplate, rat-
4 ing label, or the specifications sec-
tion in this manual).
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
+ loaded properly.

 Check oil level frequently dur-

ing run-in; add oil if needed.
After one hour (minimum), place
A/V control in minimum position,
then shut down grid to remove load.
Run engine several minutes at no
load.
 Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0684

OM-497 Page 60 Return To Table Of Contents

 SECTION 12 − GENERATOR POWER GUIDELINES

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

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
Insulated Equipment
 Do not use 2-prong plug un-
less equipment is double in-
sulated.

Be sure equipment
OR
has this symbol
and/or wording.

gen_pwr 11/02 − Ref. ST-159 730 / 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.
1 Equipment Grounding
Terminal (On Front Panel)
2 Grounding Cable (Not
Supplied)
1 3 Metal Vehicle Frame
GND/PE 2 Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
 If unit does not have GFCI re-
3 ceptacles, use GFCI-pro-
tected extension cord.

Electrically bond generator

frame to vehicle frame by
metal-to-metal contact.

 Bed liners, shipping skids, and some running

gear insulate the welding generator from the ve-
hicle frame. Always connect a ground wire from
the generator equipment grounding terminal to
bare metal on the vehicle frame as shown. S-0854

Return To Table Of Contents OM-497 Page 61

12-3. Grounding When Supplying Building Systems
1 Equipment Grounding
Terminal
1 2
2 Grounding Cable
GND/PE
Use #10 AWG or larger insulated
copper wire.
3 Ground Device
 Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.

Use ground device as stated

in electrical codes.
2 3

ST-800 576-B

12-4. How Much Power Does Equipment Require?

1 Resistive Load
3 A light bulb is a resistive load and
VOLTS 115 requires a constant amount of power.
2 AMPS 4.5
1 Hz 60 2 Non-Resistive Load
Equipment with a motor is a non-re-
sistive load and requires approxi-
mately six times more power while
starting the motor than when running
(see Section 12-8).
3 Rating Data
3
Rating shows volts and amperes, or
watts required to run equipment.

AMPERES x VOLTS = WATTS

EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.

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

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

The total load applied by the three flood lamps and drill is 1120 watts.
S-0623

OM-497 Page 62 Return To Table Of Contents

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

Return To Table Of Contents OM-497 Page 63

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-497 Page 64 Return To Table Of Contents

12-8. Power Required To Start Motor
4 1 Motor Start Code
AC MOTOR 2 2 Running Amperage
1 VOLTS 230 AMPS 2.5
3 Motor HP
3 CODE M Hz 60
4 Motor Voltage
HP 1/4 PHASE 1
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amper-
age (see example).
Welding generator amperage out-
put must be at least twice the
Single-Phase Induction Motor Starting Requirements motor’s running amperage.

Motor Start
Code G H J K L M N P

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

kVA/HP x HP x 1000
= STARTING AMPERAGE
VOLTS
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2

11.2 x 1/4 x 1000

= 12.2 A Starting the motor requires 12.2 amperes.
230 S-0624

12-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.
2 5 Second Rule
1
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
2 supply.

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

Return To Table Of Contents OM-497 Page 65

12-10. Typical Connections To Supply Standby Power

 Properly install and ground this equipment according to

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

1 2 3 4
Fused
Utility Welding
Disconnect
Electrical Transfer Switch Generator
Switch
Service Output
(If Required)

Essential
Loads

 Have only qualified persons perform Switch transfers the electrical load from Connect generator with temporary or perma-
these connections according to all electric utility service to the generator. Trans- nent wiring suitable for the installation.
applicable codes and safety practic- fer load back to electric utility when service is
es. restored. Turn off or unplug all equipment connected to
generator before starting or stopping engine.
 Properly install and ground this Install correct switch (customer-supplied). When starting or stopping, the engine has
equipment according to its Owner’s Switch rating must be same as or greater low speed which causes low voltage and
Manual and national, state, and local than the branch overcurrent protection. frequency.
codes.
3 Fused Disconnect Switch
5 Essential Loads
 Customer-supplied equipment is re- Install correct switch (customer-supplied) if
quired if generator will supply standby required by electrical code. Generator output may not meet the electrical
power during emergencies or power out- requirements of the premises. If generator
4 Welding Generator Output
ages. does not produce enough output to meet all
Generator output voltage and wiring must be requirements, connect only essential loads
1 Utility Electrical Service
consistent with regular (utility) system volt- (pumps, freezers, heaters, etc. − See Sec-
2 Transfer Switch (Double-Throw) age and wiring. tion 12-4).

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

OM-497 Page 66 Return To Table Of Contents

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

Return To Table Of Contents OM-497 Page 67

 SECTION 13 − PARTS LIST
 Hardware is common and not
available unless listed.

15

14
3 16
2
17
13
1

12
18

4 11
5 6 19

9
10
8
7

109 (CV)

108 (CV)

12 21
102 (Fig. 13-7) 20

103 95
101 22

111
93
107
100 (FIG. 13-2 OR 13-3)
99

96 94
98 (CC ONLY)

105 104 97

106 (FIG. 13-4 OR 13-5)

CC CC Models Only
CV CC/CV Models Only

Figure 13-1. Main Assembly

OM-497 Page 68 Return To Table Of Contents
 47

29 44 46
30

25
28
27 45
26
24 48

23 43 50
51
110

42
49

41
31
32
40

39
38
37
56 52
36 57
35 53
58
34
54
33 (Fig. 13-6) 59 55
66
67 60
61
68 62
71 70 69
63
64
77
65
75 76
87
88 74
84
85 89
86 72
73
78
90
83
79

91
92 82

93 81 80

802 559-E

Return To Table Of Contents OM-497 Page 69

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-1. Main Assembly

. . . 1 . . . . . . . . . . . . . 189 824 . . PANEL, gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 1 . . . . . . . . . . . . ♦199 294 . . PANEL, gen LH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 191 623 . . LABEL, warning all panels must be in place while running . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . +189 828 . . PANEL, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . ♦+199 301 . . PANEL, engine side ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . CC202 151 . . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . CV201 514 . . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . 1T . . . . 038 621 . . BLOCK, term 30A 4 pole frict term str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 038 620 . . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . 081 499 . . BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 206 352 . . BRACE, front to center upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . SR4, SR5 . 035 704 . . RECTIFIER, integ bridge 40. amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . CB4 . . . 045 061 . . CIRCUIT BREAKER, auto reset 24vdc 7 amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . 201 697 . . PAN, reactor and rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . . 201 613 . . TRANSFORMER w/bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . ♦205 636 . . TRANSFORMER w/bracket (environmental coating) . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 173 352 . . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 3ft
. . . 13 . . . . . . . . . . . . . 189 708 . . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 191 307 . . COVER, plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 191 829 . . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 189 763 . . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 189 764 . . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192 938 . . FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *♦192 939 . . FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 189 464 . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 173 909 . . HOSE, sae .312 id x .560 od x 24.000 (order by ft) . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . 201 658 . . UPRIGHT, center assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . +200 999 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . ♦+203 382 . . BASE e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 196 220 . . BRACKET, hold down fuel tank rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 192 362 . . BRACKET, mtg nyl 1/2 conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . +201 934 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . ♦+202 640 . . COVER, top ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 189 052 . . GROMMET, plastic neck filler fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 190 198 . . . . CAP, tank screw-on 3.500 in w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 192 041 . . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 176 103 . . LABEL, use diesel fuel only (Wordless Label) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . 108 487 . . LABEL, warning falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . . 176 104 . . LABEL, warning falling equipment (Wordless Label) . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . . . . 176 230 . . LABEL, warning hot exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 105 734 . . PIPE, muffler extension elbow 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 201 592 . . PIPE, exhaust (CE rated)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 201 851 . . COVER, radiator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 191 354 . . SUPPORT, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 202 633 . . SUPPORT, cover e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 200 731 . . MANIFOLD, exhaust muffler (Included w/Engine − CE rated) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 010 875 . . CLAMP, muffler 2.000 dia u pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . Figure 13-6 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 34 . . . . . . . . . . . . . 176 106 . . LABEL, warning moving parts (Wordless Label) . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . . 191 577 . . GUARD, starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 197 370 . . BRACKET, mtg engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . 190 951 . . EDGE TRIM, styel tl750-b2 x 1/16 black w/clips 1.625 . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . 197 639 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-497 Page 70 Return To Table Of Contents

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-1. Main Assembly (Continued)

. . . 39 . . . . . . . . . . . . . 213878 . . ENGINE, Deutz dsl elec F3L2011 (includes manifold/muffler) . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *067 265 . . FILTER, oil (engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192 744 . . FILTER, fuel spin-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *066 217 . . FILTER, fuel secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *195 745 . . SWITCH, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *195 746 . . SENDER, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 179 561 . . EXTRUSION, rubber clamp/bulb 2.250lg (order by ft) . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 179 562 . . EXTRUSION, rubber clamp/bulb 3.000lg (order by ft) . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . *067 266 . . BELT, blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . 147 923 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 42 . . . . . . . . . . . . . 201 714 . . BOX, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . 201 748 . . UPRIGHT, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . ♦202 638 . . UPRIGHT, rear ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . 190 206 . . CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 46 . . . . . . . . . . . . . 190 207 . . CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . 203 430 . . BRACKET, battery holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . 190 897 . . BATTERY, stor 12V 650crk 110rsv gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . 201 006 . . BOLT, j stl .312−18 x 8.500 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 50 . . . . . . . . . . . . +201 183 . . COVER, battery access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . 202 639 . . COVER, battery access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . 176 108 . . LABEL, warning battery explosion can blind (Wordless Label) . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . 192 750 . . BASE, fuel filter w/adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 192 741 . . BLOCK, spacer mtg filter base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . 145 282 . . FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT . . . . . . . . . . . . . . . . 2
. . . 54 . . . . . . . . . . . . . 107 816 . . HOSE, SAE .250 ID x .500 OD xc oil (order by ft) . . . . . . . . . . . . . . . . . . . . 3ft
. . . . . . . . . . . . . . . . . . . 134 835 . . HOSE, SAE .312 ID X .560 OD X 31.000 (order by ft) . . . . . . . . . . . . . . 4.5ft
. . . 55 . . . . . . . . . . . . . *192 744 . . FILTER, fuel spin-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . +201 715 . . BOX, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . +197 027 . . GUARD, belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . 199 849 . . SCREW, 625-11 x 4.00hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 59 . . . . . . . . . . . . . 071 731 . . WASHER, flat .656 ID x 2.250 OD x .187T stl pld . . . . . . . . . . . . . . . . . . . . 4
. . . 60 . . . . . . . . . . . . . 197 366 . . BRACKET, mtg engine RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 62 . . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 63 . . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 . . . . . . . . . . . . . . . . . . 4
. . . 64 . . . . . . . . . . . . . 197 373 . . BRACKET, support base RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . 135 205 . . NUT, 625-11 .94hex .76H stl pld elastic stop nut . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 199 507 . . HOSE, oil drain assy 20 in (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . 165 271 . . . . VALVE, oil drain 3/8-18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . 176 529 . . . . FITTING, hose brs barbed fem 1/2tbg x 3/8NPT . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 113 854 . . . . HOSE, SAE .500 ID x .780 OD xc oil (order by ft) . . . . . . . . . . . . . . . . . . 2ft
. . . 69 . . . . . . . . . . . . . 176 528 . . FITTING, hose brs barbed elbow fem 1/2 tbg x 1/2 NPT . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . 173 336 . . FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . . . . . . . . . . . WASHER, oil drain (available through engine manufacturer) . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . 173 929 . . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . TS1 . . ♦174 064 . . IDLE SOLENOID ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . 190 992 . . KEEPER, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . 190 076 . . CHANNEL, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . ♦202 635 . . CHANNEL, stiffener engine access e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . 199 592 . . LATCH, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . 215 233 . . LABEL, diesel engine maintenance Deutz (Wordless Label) . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . +200 989 . . DOOR, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . +210 736 . . DOOR, engine access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . 189 975 . . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Return To Table Of Contents OM-497 Page 71

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-1. Main Assembly (Continued)

. . . 80 . . . . . . . . . . . . . 208 141 . . STOP, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 81 . . . . . . . . . . . . . 189 826 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 81 . . . . . . . . . . . . . 199 298 . . PANEL, rocker ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . 189 827 . . PANEL, gen RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . 199 300 . . PANEL, gen RH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . 191 626 . . BUMPER, door engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 84 . . . . . . . . . . . . . 189 245 . . TANK, fuel 23gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 084 173 . . . . CLAMP, hose .460 − .545clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 86 . . . . . . . . . . . . . 189 912 . . . . FITTING, stl barbed elbow w/.047 in orf zinc pld . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . 189 909 . . . . FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . 189 913 . . . . FITTING, stl barbed elbow zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . 190 142 . . . . SENDER, fuel gauge 9.7500 deep tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . 189 910 . . . . FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . . 189 908 . . . . VALVE, drain fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . . 181 572 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . 191 446 . . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . . . 6ft
. . . 94 . . . . . . . . . . . . . 191 897 . . BRACKET, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 95 . . . . . . . . . . . . . 191 512 . . BRACKET, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . . . . . . . . . 190 250 . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 96 . . . . . . . . . . . . . 200 864 . . LABEL, warning do not weld on base (Wordless Label) . . . . . . . . . . . . . . . 2
. . . 97 . . . . . . . . . . . . . 190 179 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . R2 . . . CC189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . R3 . . . . 189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . Figure 13-2, Figure 13-3 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . 189 731 . . FIREWALL, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . Figure 13-7 . . MAIN RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . 191 448 . . TOP, cover front upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . ♦199 305 . . TOP, cover front upright ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . . . . . . . +201 750 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . . . . . . ♦+202 637 . . UPRIGHT, front ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . 134 792 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . 176 105 . . LABEL, warning general precautionary (Wordless Label) . . . . . . . . . . . . . . 1
. . 106 . . . . . Figure 13-4, Figure 13-5 PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . . . . . . . . . . . 202130 . . XFMR, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . CV193 453 . . BRACKET, mtg box fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . PC1 . . CV189 143 . . MODULE, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 110 . . . . . . . . . . . +147 923 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . 1
. . 111 . . . . . . . . . . . . 212 944 . . LABEL, cc stick overlap weld ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 190 058 . . NUT, .250-20 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . 049 525 . . NUT, 312-18 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . 192 505 . . KIT, label (includes safety and informational labels) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 062 . . KIT, label (includes safety and informational labels) (Wordless Labels) . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 192 505 or Label Kit 201 062 (Wordless Labels).
* Recommended Spare Parts.
C CC models only.
C

C
V CC/CV models only.
♦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-497 Page 72 Return To Table Of Contents

 14 4

18

6
21
3
17

7 8

2
22
1 20

23
15
11
10
19

16 5
13
12 802 551-E

Figure 13-2. Control Box Assembly − CC Models

Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 100)

. . . 1 . . . F1, F2 . . *085 874 . . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 2 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . 201 077 . . CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 201 078 . . CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 201 079 . . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . C12 . . . 191 944 . . CAPACITOR, polyp met film 10. uf 250 vac 10% . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 204 812 . . HARNESS, control box, weld control (consisting of) . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . CR7 . . . 188 636 . . . . RELAY, OCV control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . R8 . . . . 214 863 . . . . RESISTOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . SR1, SR2 . 035 704 . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . CR5 . . . 090 104 . . . . RELAY, encl 12VDC SPST 30A/15VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH, tgl spdt 15a 125vac on−none−on spd term chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 13-4) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . . 011 622 . . . . SWITCH, tgl 3pdt 15a 125vac on−none−on spd term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 13-4) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . . . . . 1
. . . . . . . . . . RC3 . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . . . . . 1
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 177 859 . . . . CONN, body 5 terminal (to engine control switch S1) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 150 316 . . . . CONN, rect univ 039 6p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . 092 670 . . . . CONN, rect univ 084 3p/s 1row plug cable lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 CB11, 12, 13 139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . . 3
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 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-2. Control Box Assembly − CC Models (Continued)

. . . . . . . . . . . . . . . . . . . 190 260 . . HARNESS, unit weld control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG3 . . . 158 465 . . . . CONN, rect univ 084 12p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187 654 . . . . SEAL, wire univ 12p/s 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114 063 . . . . CONN, rect univ 084 4p/s 1row plug cable lkg . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 192 309 . . . . CLIP, snap in .630 bundle .250 hole .248 thk . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . C9 . . . . . 087 110 . . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . R6 . . . . 141 424 . . RESISTOR, ww fxd 30 w 25 ohm faston te . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . PC7 . . ♦195 706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CR4 . . ♦113 247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . . 1
. . . 17 . . . . CR6 . . ♦090104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
. . . 18 . . CR2, CR3 . 090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 206 024 . . HARNESS, engine control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . D1/C1 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . CB10 . . . 190 374 . . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 173 916 . . . . HOUSING, contact 10-pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . CR1 . . . 214 876 . . . . RELAY, encl 6vds spst 35a/14vdc 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . CB14 . . ♦205 927 . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . CR8 . . ♦155 309 . . CONTACTOR, solenoid 12VDC cont 400A inrush . . . . . . . . . . . . . . . . . . . . 1
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

4 16

19
3
15

17
11
2
20
1
18
21

12 5

13

10

14
7
6
8
9
802 360-D

Figure 13-3. Control Box Assembly − CC/CV Models

OM-497 Page 74 Return To Table Of Contents
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 100)

. . . 1 . . . F1, F2 . . *085 874 . . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 2 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . 201 077 . . CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 201 078 . . CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 201 079 . . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 134 201 . . STAND-OFF, support pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 7 . . . . PC9 . . . 192 224 . . CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . C9 . . . . . 087 110 . . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 204 811 . . HARNESS, control box, cv weld control (consisting of) . . . . . . . . . . . . . . . 1
. . . 10 . . . . SR1 . . . 035 704 . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . CR5 . . . 090 104 . . . . RELAY, encl 12VDC SPST 30A/15VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . . . . . 1
. . . . . . . . . . RC3 . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . . . . . 1
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . . 1
. . . 12 CB11, 12, 13 139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . 193 324 . . . . SWITCH, rotary 6 position gold contacts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 13-5) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH,tgl spdt 15a 125vac on−none−on spd term chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 13-5) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 150 316 . . . . CONN, rect univ 039 6p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . 177 859 . . . . CONN, body 5 terminal (to engine control switch S1) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 193 183 . . . . CONN, rect cinch 18 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 196 602 . . . . PLUG, cavity 18,30 position cinch connector . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 196 603 . . . . SEAL, switch 6 position rotary .250 shaft . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 141 450 . . . . CONN, rect metrmate 10skt 1row plug cable lkg . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . PC7 . . ♦195 706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CR4 . . ♦113 247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CR6 . . ♦090104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
. . . 16 . . CR2, CR3 . 090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 206 024 . . HARNESS, engine control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . R8 . . . . 214 863 . . . . RESISTOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . CB10 . . . 190 374 . . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 185 655 . . . . SEAL, wire univ 15P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . CR1 . . . 214 876 . . . . RELAY, encl 6vds spst 35a/14vdc 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . CB14 . . ♦205 927 . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . CR8 . . ♦155 309 . . CONTACTOR, solenoid 12VDC cont 400A inrush . . . . . . . . . . . . . . . . . . . . 1
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Return To Table Of Contents OM-497 Page 75

 4
 Hardware is common and
not available unless listed.

5
2
1
6
7
8
9

10
41 11
40

39
12
13
14

15
16
36 35
34 17
37
33 32 18
38

31
30
29
19
20
22
21

23

28

27

26 25 24 802 266-D

Figure 13-4. Panel, Front w/Components − CC Models

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 106)

. . . 1 . . . . . . . . . . . . . 201 841 . . PLATE SCREENED, ident control rating; when ordering this item,
.............................. the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 ........................ NAMEPLATE, screened (order by model and serial number) . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 201 580 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . ♦202 642 . . PANEL, engine/weld control ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . 189 382 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 202 223 . . BUS BAR, idealized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

OM-497 Page 76 Return To Table Of Contents

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-4. Panel, Front w/Components − CC Models (Continued)

. . . . . . . . . . . . . . . . . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . 188 635 . . RHEOSTAT, WW 300W 34 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 7 . . . . . S6 . . . . . 011 622 . . SWITCH, tgl DPDT 15A 125VAC (included in control box harness,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Figure 13-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see Figure 13-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . RC13 . . . 032 897 . . RECEPTACLE, twlk grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S1 . . . . 176 606 . . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S2 . . . . 021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . MS1 . . . 189 698 . . SWITCH, magnetic manual reset low current . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB1 . . . 201 083 . . CIRCUIT BREAKER, man reset 2P 20 A, 250VAC . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 109 . . HARNESS, generatoriliary power (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB2 . . . 093 996 . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . 3
. . . 15 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . 1
. . . 16 . . . . RC1 . . . 147 632 . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 190 861 . . LABEL, warning electric shock and moving parts . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . +201 106 . . PANEL, gen pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . ♦+202 641 . . PANEL, gen pwr ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 083 030 . . STUD, brs .250−20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . 601 836 . . NUT, 250−20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 21 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . ♦199 303 . . PANEL, mtg terminal pwr output ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . ♦210750 . . PANEL, mtg terminal pwr output ss CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 193 260 . . COVER, receptacle 2.250 dia lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 193 258 . . COVER, receptacle GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . 193 143 . . BOOT, magnetic shutdown switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 119 014 . . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . PL1 . . . 191 241 . . LED, red 12V 4 ind lights panel mtg round . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . FUEL . . . 192 265 . . GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . HM . . . . . 118 058 . . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . 019 602 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 024 103 . . BLANK, snap−in nyl .750 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 192 505 or Label Kit 201 062 (Wordless Labels).
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.

Return To Table Of Contents OM-497 Page 77

  Hardware is common and
not available unless listed. 4

5
6
2 7
8
1 9
10
58

57 11
56 12
13
55 14
15
16
54 17

18

19
20
34 21

51
52 50 22
49 31
53 48 30
33 23
47
24
46
32 26
29
44
28 25
45 27

35

36

43
37

42

41 40 39 38

Figure 13-5. Panel, Front w/Components − CC/CV Models 802 332-F

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 106)

. . . 1 . . . . . . . . . . . . . 201 579 . . PLATE SCREENED, ident control; when ordering this item,
.............................. the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 ........................ NAMEPLATE, screened (order by model and serial number) . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 201 580 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . ♦202 642 . . PANEL, engine/weld control ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . 189 382 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦202 223 . . BUS BAR, idealized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

OM-497 Page 78 Return To Table Of Contents

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)

. . . . . . . . . . . . . . . . . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . . 193 118 . . POT, cp flat 1t 2w 1k ohm linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . S6 . . . . 193 234 . . SWITCH, rotary 6 position gold contacts (included in control box harness,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Figure 13-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see Figure 13-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . PC6 . . . 192 995 . . CIRCUIT CARD ASSY, connector/receptacle . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CB5 . . . 139 266 . . CIRCUIT BREAKER, man reset 1p 15a 250vac frict . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S1 . . . . 176 606 . . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . S2 . . . . 021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . MS1 . . . 189 698 . . SWITCH, magnetic manual reset low current . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB1 . . . 201 083 . . CIRCUIT BREAKER, man reset 2P 20 A, 250VAC . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 109 . . HARNESS, generator power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CB2 . . . 093 996 . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . 1
. . . 16 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC1 . . . 147 632 . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . RC5 . . ♦182 954 . . RCPT, str 3P4W 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . ♦025 248 . . STAND-OFF, insul .250-20 x 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . ♦604 102 . . CONNECTOR, clamp cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . ♦197 527 . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦197 363 . . TERMINAL, ring tng screw clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . CB7 . . ♦196 780 . . CIRCUIT BREAKER, man reset 3p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . +201 106 . . PANEL, generator power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . +♦201 107 . . PANEL, generator power (full kVA option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . ♦196 781 . . BOOT, circuit breaker 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . ♦197 508 . . PLUG, protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . ♦077 440 . . BUSHING, conduit 1 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 601 836 . . NUT, 250−20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 39 . . . . . . . . . . . . ♦197 291 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 083 030 . . STUD, brs .250−20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CT2 . . ♦197 433 . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 190 861 . . LABEL, warning electric shock and moving parts . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . ♦197 399 . . LABEL, warning 3 ph generator power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 193 260 . . COVER, receptacle 2.250 dia lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . 193 258 . . COVER, receptacle GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S12 . . ♦203 233 . . SWITCH, polarity/AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . PC4, PC5 . 189 744 . . CIRCUIT CARD ASSEMBLY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 39 . . . . . . . . . . . . . 134 201 . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 40 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 41 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 42 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . 193 143 . . BOOT, magnetic shutdown switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 119 014 . . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 50 . . . . . . . . . . . . . 170 391 . . CONN, circ ms protective cap size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Return To Table Of Contents OM-497 Page 79
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-5. Panel, Front w/Components − CC/CV Models (Continued)

. . . 51 . . . . . PL1 . . . 191 241 . . LED, red 12V 4 ind lights panel mtg round . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . FUEL . . . 192 265 . . GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . HM . . . . . 118 058 . . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . 097 922 . . KNOB, pointer .875 dia x .250 ID w/set screws plstc . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . 097 924 . . KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . CB6 . . . 083 432 . . CIRCUIT BREAKER, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 193 158 . . HARNESS, unit weld control − CV (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114 063 . . . . CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . 193 184 . . . . CONNECTOR, rect cinch 30 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . 147 992 . . . . CONNECTOR, rect univ 039 10p/s 2 row plug cable . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . 158 465 . . . . CONNECTOR, rect univ 084 12p/s 3 row plug cable . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 088 731 . . . . BUSHING, snap-in nyl .375 ID x .500 mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 135 873 . . . . CLIP, conduit convoluted 1/2 in mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 187 654 . . . . SEAL, wire univ 12p/s 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 024 103 . . BLANK, snap-in nyl .750 mtg hole blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 120 304 . . BLANK, snap−in nyl .250 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 192 505 or Label Kit 201 062 (Wordless Labels).
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.

20

17
16 18
11
15

12
21

9 10 14
13

19
8
22
23
7
6

5
3 24
25
4 26
2 27
1
28
30 29
31
32
33
34
35
36 802 552-B

Figure 13-6. Generator

OM-497 Page 80 Return To Table Of Contents
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 13-6. Generator (Figure 13-1 Item 33)

. . . 1 . . . . . . . . . . . . . 132 053 . . SCREW, .375−16x1.50 hex hd−pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . 2 . . . . . . . . . . . . . 183 387 . . WASHER, conical spring .406 ID x .875 OD pltd . . . . . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 195 911 . . ENDBELL, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 143 220 . . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 201 099 . . STATOR, exciter/gen pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . +201 110 . . STATOR, weld assembly complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . +♦201 089 . . STATOR, weld assembly complete (full kVA option) . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . 176 106 . . LABEL, warning moving parts (CE models only) . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . 190 197 . . GUARD, generator wire mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 172 674 . . SPRING, ext .240 OD x .041 wire x 3.500pld . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . 039 207 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . ROTOR . . 212 996 . . ROTOR, Generator Segmented Assy (Includes) . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 210 824 . . . . ROTOR, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 024 617 . . . . . . RING, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 053 390 . . . . . . BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HUB, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 210 447 . . . . FAN, Rotor Assy Generator (Segmented) (includes) . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 210 332 . . . . . . PLATE, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 206 242 . . . . . . FAN, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . 049 026 . . . . . . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . 10
. . . 18 . . . . . . . . . . . . . 083 883 . . . . . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . 10
. . . 19 . . . . . . . . . . . . . 080 389 . . . . . . SCREW, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . 8
. . . 20 . . . . . . . . . . . . . 195 748 . . . . FLYWHEEL, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 193 256 . . ADAPTER, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 083 883 . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . 4
. . . 23 . . . . . . . . . . . . . 049 026 . . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 24 . . . . . . . . . . . . . 191 579 . . COVER, starter hole Perkins/Continental . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 195 560 . . GUARD, starter hole deutz 912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 083 883 . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . 6
. . . 26 . . . . . . . . . . . . . 172 555 . . SCREW, M10-1.5 x 50hexhd pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 27 . . . . . . . . . . . . . 602 159 . . SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw . . . . . . . . . . . . . 6
. . . 28 . . . . . . . . . . . . . 601 961 . . SCREW, .312-18 x 2.25hexhd pln gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 29 . . . . . . . . . . . . . . 602 211 . . WASHER, lock .318 ID x 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 30 . . . . . . . . . . . . . 139 341 . . WASHER, exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 31 . . . . . . . . . . . . . *190 823 . . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 32 . . . . . . . . . . . . . 208 469 . . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 33 . . . . . . . . . . . . . 189 142 . . BRUSHHOLDER ASSEMBLY, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 602 242 . . WASHER, flat .375IDx0.875odx.083t stl pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . . . 602 211 . . WASHER, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . 2
. . . 36 . . . . . . . . . . . . . 604 534 . . SCREW, .312−18x1.25 hex hd−pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 190 259 . . HARNESS, brush (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . 168 071 . . . . CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187 651 . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 192 505 or Label Kit 201 062 (Wordless Labels).
*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.

Return To Table Of Contents OM-497 Page 81

  Hardware is common and 4
not available unless listed.
3

1
5

802 279-A

Figure 13-7. Main Rectifier Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 13-7. Main Rectifier Assembly (Figure 13-1 Item 102)

. . . . . . . . . . SR3 . . . 201 747 . . RECTIFIER (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . SR3 . . ♦203 381 . . RECTIFIER, environmental (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . . 188 137 . . . . CONNECTION BOARD, rectifier AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 188 517 . . . . BUS BAR, connection board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . . . . . . . . . . . . 188 135 . . . . ENCLOSURE, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 134 201 . . . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . PC3 . . . 201 449 . . . . CIRCUIT CARD ASSEMBLY, protection . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 188 136 . . . . INSULATOR, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 7 . . . . . . . . . . . . . 188 493 . . . . HEAT SINK, rectifier al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . D3, D5, D7 208 334 . . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 208 335 . . . . DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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-497 Page 82 Return To Table Of Contents

 Effective January 1, 2003
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.

Call LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold
* APT & SAF Model Plasma Cutting Torches
for your local after the effective date of this limited warranty is free of defects * Remote Controls
in material and workmanship at the time it is shipped by Miller. * Accessory Kits
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or * Canvas Covers
Your distributor also gives replace any warranted parts or components that fail due to
you ... Miller’s True Blue Limited Warranty shall not apply to:
such defects in material or workmanship. Miller must be
Service notified in writing within thirty (30) days of such defect or 1. Consumable components; such as contact tips,
failure, at which time Miller will provide instructions on the cutting nozzles, contactors, brushes, slip rings,
You always get the fast,
warranty claim procedures to be followed. relays or parts that fail due to normal wear.
reliable response you (Exception: brushes, slip rings, and relays are
need. Most replacement Miller shall honor warranty claims on warranted equipment
covered on Bobcat, Trailblazer, and Legend models.)
parts can be in your listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that 2. Items furnished by Miller, but manufactured by others,
hands in 24 hours. the equipment was delivered to the original retail purchaser, or such as engines or trade accessories. These items are
Support one year after the equipment is sent to a North American covered by the manufacturer’s warranty, if any.
Need fast answers to the distributor or eighteen months after the equipment is sent to an
International distributor. 3. Equipment that has been modified by any party other
tough welding questions? than Miller, or equipment that has been improperly
Contact your distributor. 1. 5 Years Parts — 3 Years Labor installed, improperly operated or misused based upon
The expertise of the * Original main power rectifiers industry standards, or equipment which has not had
distributor and Miller is reasonable and necessary maintenance, or equipment
* Inverters (input and output rectifiers only) which has been used for operation outside of the
there to help you, every
2. 3 Years — Parts and Labor specifications for the equipment.
step of the way.
* Transformer/Rectifier Power Sources MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Plasma Arc Cutting Power Sources PERSONS TRAINED AND EXPERIENCED IN THE USE
* Semi-Automatic and Automatic Wire Feeders AND MAINTENANCE OF WELDING EQUIPMENT.
* Inverter Power Supplies In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
* Maxstar 150 appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
3. 1 Year — Parts and Labor Unless Specified replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
* Motor Driven Guns (w/exception of Spoolmate transportation costs of any kind will be allowed.
Spoolguns)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Process Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Positioners and Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* RFCS Foot Controls PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources ANY OTHER LEGAL THEORY.
* Water Coolant Systems ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
* Flowgauge and Flowmeter Regulators (No Labor)
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,
* Maxstar 85, 140 OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Spot Welders OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Load Banks PURPOSE, WITH RESPECT TO ANY AND ALL
* Racks EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
* Running Gear/Trailers DISCLAIMED BY MILLER.
* Plasma Cutting Torches (except APT & SAF Some states in the U.S.A. do not allow limitations of how long
Models) an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
* Field Options limitation or exclusion may not apply to you. This warranty
(NOTE: Field options are covered under True provides specific legal rights, and other rights may be
Blue for the remaining warranty period of the available, but may vary from state to state.
product they are installed in, or for a minimum of
one year — whichever is greater.) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
5. 90 Days — Parts Warranty provides specific legal rights, and other rights may
* MIG Guns/TIG Torches be available, but may vary from province to province.

miller_warr 8/03
 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
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate 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
European Headquarters −
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com

Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

PRINTED IN USA  2003 Miller Electric Mfg. Co. 1/03