Miller Electric Welding System Big 40 CAT User Manual

OM-4406

202 759T

January 2004

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 40 CAT

(CE Compliant)

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www.MillerWelds.com

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TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Manufacture r ’s Rating Labels For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-8. Optional Three-Phase Generator Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-9. Volt-Ampere Curve For CC/CV Models In AC TIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5-1. Installing Welding Generator (See Sections 5-2 And 5-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5-2. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5-5. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5-6. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5-7. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5-8. Connecting T o Weld Output T e rminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5-10. Connecting T o R emote Amperage Adjust Receptacle RC13 On CC Models . . . . . . . . . . . . . . . . . . . . . 29

5-1 1 . Connecting T o R emote 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

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TABLE OF CONTENTS

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

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

8-1. 120 Volt And 240 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8-2. Connecting T o O ptional 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. Caterpillar Customer Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

9-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9-6. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

9-7. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9-8. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

9-9. Diagnosing Causes Of Engine Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

9-10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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Declaration of Conformity for

European Community (CE) Products

This information is provided for units with CE certification (see rating label on unit).

NOTE

Manufacturer’s Name:

Miller Electric Mfg. Co.

1635 W. Spencer Street

Appleton, WI 54914 USA

Manufacturer’s Address:

Declares that the product:

Big 40 CAT

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

Machinery Directives: 98/37/EEC,91/368/EEC, 93/C 133/04, 93/68/EEC

Noise Level Of Welding Generators: 2000/14/EC

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC

Standards

Safety Requirements for Arc Welding Equipment IEC 60974-1: 1998-09

Rotating Electrical Machines − Part 1: Rating and Performance: IEC 34-1: 1994

Rotating Electrical Machines − Part 5: Classification of degrees of protection provided by enclosure of rotating

electrical machines (IP code): IEC 34-5: 1991

Insulation coordination for equipment within low-voltage systems:

Part 1: Principles, requirements and test: IEC 60664-1: 2000-04

Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995

European Contact:

Mr. Danilo Fedolfi, Managing Director

ITW WELDING PRODUCTS ITALY S.r.l.

Via Privata Iseo 6/E

20098 San Giuliano

Milanese, Italy

Telephone:

Fax:

39(02)98290-1

39(02)98290-203

dec_con1_11/02

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Declaration of Conformity for

European Community (CE) Products

This information is provided for units with CE certification (see rating label on unit).

NOTE

Manufacturer’s Name:

Miller Electric Mfg. Co.

Manufacturer’s Address:

1635 W. Spencer Street

Appleton, WI 54914 USA

Declares that the product:

Big 40 CAT

conforms to the following Directives and Standards relating to sound levels:

Directives

Noise Level Of Welding Generators: 2000/14/EC

Sound Level Information

Measured Sound Power Level: 98 dB

Guaranteed Sound Power Level: 98 dB

This equipment conforms to requirements brought forth by 2000/14/EC

Noise conformity assessment procedure followed with notified body:

AV Technology Limited

AVTECH House

Birdhall Lane

Cheadle Heath

Stockport

Cheshire

SK3OXU

Sound power level requirements determined by the 40% duty cycle of 500 A, 30 V

Conforming assessment procedure 1 of Annex VI will be followed.

European Contact:

Mr. Danilo Fedolfi, Managing Director

ITW WELDING PRODUCTS ITALY S.r.l.

Via Privata Iseo 6/E

20098 San Giuliano

Milanese, Italy

Telephone:

Fax:

39(02)98290-1

39(02)98290203

dec_con1_sound11/02

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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom _nd_8/03

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.

This group of symbols means Warning! Watch Out! possible

Marks a special safety message.

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

“

”

;

1-2. Arc Welding Hazards

Use only well-maintained equipment. Repair or replace damaged parts at

once. Maintain unit according to manual.

The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see the

symbol, watch out, and follow the related instructions to avoid the

hazard. The safety information given below is only a summary of

the more complete safety information found in the Safety Stan-

dards listed in Section 1-7. Read and follow all Safety Standards.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

Clamp work cable with good metal-to-metal contact to workpiece or work-

table as near the weld as practical.

Only qualified persons should install, operate, maintain, and re-

pair this unit.

Insulate work clamp when not connected to workpiece to prevent contact

with any metal object.

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

output terminal.

During operation, keep everybody, especially children, away.

SIGNIFICANT DC VOLTAGE exists in inverters after stop-

ping engine.

ELECTRIC SHOCK can kill.

Stop engine on inverter and discharge input capacitors according to

instructions in Maintenance Section before touching any parts.

Touching live electrical parts can cause fatal shocks or

severe burns. The electrode and work circuit is electrically

live whenever the output is on. The input power circuit and

machine internal circuits are also live when power is on. In semiautomatic or

automatic wire welding, the wire, wire reel, drive roll housing, and all metal

parts touching the welding wire are electrically live. Incorrectly installed or

improperly grounded equipment is a hazard.

FUMES AND GASES can be hazardous.

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

fumes and gases.

Insulate yourself from work and ground using dry insulating mats or covers

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

If ventilation is poor, use an approved air-supplied respirator.

Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s

instructions for metals, consumables, coatings, cleaners, and degreasers.

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

danger of falling.

Use AC output ONLY if required for the welding process.

Work in a confined space only if it is well ventilated, or while wearing an air-

supplied respirator. Always have a trained watchperson nearby. Welding

fumes and gases can displace air and lower the oxygen level causing injury

or death. Be sure the breathing air is safe.

If AC output is required, use remote output control if present on unit.

Additionalsafety precautions are required when any of the following electri-

cally hazardous conditions are present: in damp locations or while wearing

wet clothing; on metal structures such as floors, gratings, or scaffolds;

when in cramped positions such as sitting, kneeling, or lying; or when there

is a high risk of unavoidable or accidental contact with the workpiece or

ground. For these conditions, use the following equipment in order present-

ed: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most

situations, use of a DC, constant voltage wire welder is recommended.

And, do not work alone!

Do not weld in locations near degreasing, cleaning, or spraying operations.

The heat and rays of the arc can react with vapors to form highly toxic and

irritating gases.

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

steel, unless the coating is removed from the weld area, the area is well

ventilated, and if necessary, while wearing an air-supplied respirator. The

coatings and any metals containing these elements can give off toxic fumes

if welded.

Disconnect input power or stop engine before installing or servicing this

equipment. Lockout/tagout input power according to OSHA 29 CFR

1910.147 (see Safety Standards).

BUILDUP OF GAS can injure or kill.

Shut off shielding gas supply when not in use.

Always ventilate confined spaces or use approved

air-supplied respirator.

Properly install and ground this equipment according to its Owner’s Manual

and national, state, and local codes.

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

and invisible (ultraviolet and infrared) rays that can burn eyes

and skin. Sparks fly off from the weld.

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

cord immediately if damaged — bare wiring can kill.

Turn off all equipment when not in use.

Wear a welding helmet fitted with a proper shade of filter to protect your face

and eyes from arc rays and sparks when welding or watching (see ANSI

Z49.1 and Z87.1 listed in Safety Standards).

Do not use worn, damaged, undersized, or poorly spliced cables.

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-

arate cable.

Use protective screens or barriers to protect others from flash and glare;

warn others not to watch the arc.

Do not touch electrode if you are in contact with the work, ground, or anoth-

er electrode from a different machine.

Wear protective clothing made from durable, flame-resistant material (wool

and leather) and foot protection.

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OM-4406 Page 1

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WELDING can cause fire or explosion.

HOT PARTS can cause severe burns.

Allow cooling period before maintaining.

Wear protective gloves and clothing when working on

a hot engine.

Do not touch hot engine parts or just-welded parts

bare-handed.

Welding on closed containers, such as tanks, drums, or

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

welding arc. The flying sparks, hot workpiece, and hot

equipment can cause fires and burns. Accidental contact of electrode to metal

objects can cause sparks, explosion, overheating, or fire. Check and be sure

the area is safe before doing any welding.

Protect yourself and others from flying sparks and hot metal.

Do not weld where flying sparks can strike flammable material.

NOISE can damage hearing.

Noise from some processes or equipment can damage

hearing.

Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not

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.

MAGNETIC FIELDS can affect pacemakers.

Watch for fire, and keep a fire extinguisher nearby.

Pacemaker wearers keep away.

Be aware that welding on a ceiling, floor, bulkhead, or partition can cause

fire on the hidden side.

Wearers should consult their doctor before going

near arc welding, gouging, or spot welding opera-

tions.

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

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

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

prevent welding current from traveling long, possibly unknown paths and

causing electric shock and fire hazards.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If

damaged, a cylinder can explode. Since gas cylinders are

normally part of the welding process, be sure to treat them

carefully.

Do not use welder to thaw frozen pipes.

Remove stick electrode from holder or cut off welding wire at contact tip

when not in use.

Protect compressed gas cylinders from excessive heat, mechanical

shocks, slag, open flames, sparks, and arcs.

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

fless trousers, high shoes, and a cap.

Install cylinders in an upright position by securing to a stationary support or

cylinder rack to prevent falling or tipping.

Remove any combustibles, such as a butane lighter or matches, from your

person before doing any welding.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

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

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-

signed for the specific application; maintain them and associated parts in

good condition.

FLYING METAL can injure eyes.

Welding, chipping, wire brushing, and grinding cause

sparks and flying metal. As welds cool, they can

throw off slag.

Turn face away from valve outlet when opening cylinder valve.

Keep protective cap in place over valve except when cylinder is in use or

connected for use.

Wear approved safety glasses with side shields even

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

MOVING PARTS can cause injury.

BATTERY EXPLOSION can BLIND.

Keep away from fans, belts, and rotors.

Keep all doors, panels, covers, and guards closed

and securely in place.

Always wear a face shield, rubber gloves, and protec-

tive clothing when working on a battery.

Stop engine before disconnecting or connecting bat-

tery cables or servicing battery.

Stop engine before installing or connecting unit.

Do not allow tools to cause sparks when working on a battery.

Do not use welder to charge batteries or jump start vehicles.

Observe correct polarity (+ and −) on batteries.

Have only qualified people remove guards or covers for maintenance

and troubleshooting as necessary.

To prevent accidental starting during servicing, disconnect negative (−)

battery cable from battery.

Disconnect negative (−) cable first and connect it last.

Keep hands, hair, loose clothing, and tools away from moving parts.

Reinstall panels or guards and close doors when servicing is finished

and before starting engine.

FUEL can cause fire or explosion.

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

engine from kicking back or starting.

Stop engine and let it cool off before checking or add-

ing fuel.

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

sparks or open flames.

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

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-4406 Page 2

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BATTERY ACID can BURN SKIN and EYES.

STEAM AND HOT COOLANT can burn.

Do not tip battery.

Replace damaged battery.

If possible, check coolant level when engine is cold to

avoid scalding.

Always check coolant level at overflow tank, if pres-

ent on unit, instead of radiator (unless told otherwise

in maintenance section or engine manual).

Flush eyes and skin immediately with water.

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

surfaces or flammables.

Turn cap slightly and let pressure escape slowly before completely re-

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-

eas.

Do not let engine exhaust sparks cause fire.

Use approved engine exhaust spark arrestor in re-

quired areas — see applicable codes.

If used in a closed area, vent engine exhaust outside

and away from any building air intakes.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can

cause serious injury or death.

HOT METAL from air arc cutting and

gouging can cause fire or explosion.

Do not use compressed air for breathing.

Use only for cutting, gouging, and tools.

Do not cut or gouge near flammables.

Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury.

COMPRESSED AIR can cause injury.

Do not touch hot compressor or air system parts.

Let system cool down before touching or servicing.

Wear approved safety goggles.

Do not direct air stream toward self or others.

TRAPPED AIR PRESSURE AND WHIPPING

HOSES can cause injury.

READ INSTRUCTIONS.

Read Owner’s Manual before using or servicing unit.

Stop engine and release air pressure before

servicing.

Release air pressure from tools and system before

servicing, adding or changing attachments, or open-

ing compressor oil drain or oil fill cap.

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

OVERUSE can cause OVERHEATING.

FALLING UNIT can cause injury.

Allow cooling period; follow rated duty cycle.

Reduce current or reduce duty cycle before starting

to weld again.

Use lifting eye to lift unit only, NOT running gear, gas

cylinders, trailer, or any other accessories.

Use equipment of adequate capacity to lift and

support unit.

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

enough to extend beyond opposite side of unit.

Do not block or filter airflow to unit.

OVERHEATING can damage motors.

STATIC (ESD) can damage PC boards.

Turn off or unplug equipment before starting or stop-

ping engine.

Do not let low voltage and frequency caused by low

engine speed damage electric motors.

Put on grounded wrist strap BEFORE handling

boards or parts.

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

guards in a safe location wearing proper face, hand,

and body protection.

Use tongue jack or blocks to support weight.

Properly install welding generator onto trailer accord-

ing to instructions supplied with trailer.

Sparks can cause fires — keep flammables away.

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OM-4406 Page 3

READ INSTRUCTIONS.

ARC WELDING can cause interference.

Use only genuine MILLER/Hobart replacement

parts.

Electromagnetic energy can interfere with sensitive

electronic equipment such as microprocessors,

computers, and computer-driven equipment such as

robots.

Be sure all equipment in the welding area is electro-

magnetically compatible.

Perform engine and air compressor (if applicable)

maintenance and service according to this manual

and the engine/air compressor (if applicable) manu-

als.

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

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

H.F. RADIATION can cause interference.

Locate welding operation 100 meters from any sensitive electronic

equipment.

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

tion, safety services, computers, and communica-

tions equipment.

Be sure this welding machine is installed and grounded according to this

manual.

Have only qualified persons familiar with electronic

equipment perform this installation.

If interference still occurs, the user must take extra measures such as

moving the welding machine, using shielded cables, using line filters, or

shielding the work area.

The user is responsible for having

qualified electrician

promptly correct any interference problem resulting from the installation.

If notified by the FCC about interference, stop using the equipment at

once.

Have the installation regularly checked and maintained.

Keep high-frequency source doors and panels tightly shut, keep spark

gaps at correct setting, and use grounding and shielding to minimize the

possibility of interference.

1-6. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California Health &

Safety Code Section 25249.5 et seq.)

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive

harm.

For Diesel Engines:

Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductiveharm. Wash hands after handling.

Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

1-7. Principal Safety Standards

Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,

from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

(phone: 305-443-9353, website: www.aws.org).

RecommendedSafe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-

ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).

levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or

in Toronto 416-747-4044, website: www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11

West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,

website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:

617-770-3000,website: www.nfpa.org and www. sparky.org).

NationalElectrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA

02269-9101(phone: 617-770-3000, website: www.nfpa.org and www.

sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1735 Jefferson Davis Highway,

Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:

www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

CanadianStandards Association, Standards Sales, 178 Rexdale Bou-

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there

are 10 Regional Offices—phone for Region 5, Chicago, is

312-353-2220,website: www.osha.gov).

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

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

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

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

operator as practical.

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

possible.

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined.Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

OM-4406 Page 4

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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_fre 8/03

−

2-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure

présente des risques de danger ! Ceux-ci sont identifiés par

des symboles adjacents aux directives.

Ce groupe de symboles si-

gnifie Mise en garde

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-

sous afin de connaître les mesures à prendre pour éviter tout danger.

;

’

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

En effectuant les raccordements d’entrée fixer d’abord le conducteur de

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

Les symboles présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les ris-

ques de danger. Lorsque vous voyez un symbole, soyez

vigilant et suivez les directives mentionnées afin d’éviter tout

danger. Les consignes de sécurité présentées ci-après ne font

que résumer l’information contenue dans les normes de sécu-

rité énumérées à la section 2-6 . Veuillez lire et respecter toutes

ces normes de sécurité.

Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas en-

dommagé ou dénudé − remplacer le cordon immédiatement s’il est

endommagé − un câble dénudé peut provoquer une électrocution.

Mettre l’appareil hors tension quand on ne l’utilise pas.

Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou

mal épissés.

Ne pas enrouler les câbles autour du corps.

L’installation, l’utilisation, l’entretien et les réparations ne

doivent être confiés qu’à des personnes qualifiées.

Si la pièce soudée doit être mise à la terre, le faire directement avec un

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

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

une électrode provenant d’une autre machine.

Au cours de l’utilisation, tenir toute personne à l’écart et plus

particulièrement les enfants.

N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ

les pièces endommagées. Entretenir l’appareil conformément à ce

manuel.

UN CHOC ÉLECTRIQUE peut tuer.

Porter un harnais de sécurité quand on travaille en hauteur.

Maintenir solidement en place tous les panneaux et capots.

Un simple contact avec des pièces électriques peut

provoquer une électrocution ou des blessures graves.

L’électrode et le circuit de soudage sont sous tension dès

que l’appareil est sur ON. Le circuit d’entrée et les circuits

internes de l’appareil sont également sous tension à ce

Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec

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

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

avec tout objet métallique.

moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le

logement des galets d’entraînement et les pièces métalliques en contact avec

le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la

terre présentent un danger.

Une tension DC importante subsiste à l’intérieur

des onduleurs après avoir coupé l’alimentation.

Couper l’alimentation du poste et décharger les condensateurs d’entrée

comme indiqué dans la Section Maintenance avant de toucher des compo-

sants.

Ne jamais toucher les pièces électriques sous tension.

Porter des gants et des vêtements de protection secs ne comportant pas

de trous.

LES FUMÉES ET LES GAZ peuvent

être dangereux.

S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens iso-

lants suffisamment grands pour empêcher le contact physique éventuel

avec la pièce ou la terre.

Le soudage génère des fumées et des gaz. Leur inhalation

peut être dangereux pour votre santé.

Ne pas se servir de source électrique àcourant électrique dans les zones

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

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-

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

À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de

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

Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air

homologué.

Des précautions de sécurité supplémentaires sont requises dans des envi-

ronnements à risque comme: les endroits humides ou lorsque l’on porte

des vêtements mouillés; sur des structures métalliques au sol, grillages et

échafaudages; dans des positions assises, à genoux et allongées; ou

quand il y a un risque important de contact accidentel avec la pièce ou le

sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence:

1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un

poste à souder manuel (électrode enrobée) DC, 3) un poste à souder ma-

nuel AC avec tension à vide réduite. Dans la plupart des cas, un poste

courant continu de type CV est recommandé. Et, ne pas travailler seul!

Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-

tions du fabricant concernant les métaux, les consommables, les

revêtements, les nettoyants et les dégraisseurs.

Travailler dans un espace fermé seulement s’il est bien ventilé ou en por-

tant un respirateur à alimentation d’air. Demander toujours à un surveillant

dûment formé de se tenir à proximité. Des fumées et des gaz de soudage

peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des

blessures ou des accidents mortels. S’assurer que l’air de respiration ne

présente aucun danger.

Ne pas souder dans des endroits situés à proximité d’opérations de dé-

graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de

l’arc peuvent réagir en présence de vapeurs et former des gaz hautement

toxiques et irritants.

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

à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation

selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

Installer et mettre à la terre correctement cet appareil conformément à son

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

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

sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été

enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si néces-

saire, en portant un respirateur à alimentation d’air. Les revêtements et

tous les métaux renfermant ces éléments peuvent dégager des fumées

toxiques en cas de soudage.

Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que

le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre

du sectionneur ou que la fiche du cordon est raccordée à une prise

correctement mise à la terre.

OM-4406 Page 5

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Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B

pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi-

mité.

LES ACCUMULATIONS DE GAZ ris-

quent de provoquer des blessures ou

même la mort.

DES PARTICULES VOLANTES

peuvent blesser les yeux.

Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent

des étincelles et des particules métalliques vo-

Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-

rateur d’adduction d’air homologué.

lantes. Pendant la période de refroidissement des soudures, elles ris-

quent de projeter du laitier.

LES RAYONS DE L’ARC peuvent pro-

voquer des brûlures dans les yeux et

sur la peau.

Le rayonnement de l’arc du procédé de soudage génère

des rayons visibles et invisibles intenses (ultraviolets et

Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

DES PIÈCES CHAUDES peuvent

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-

tuer des travaux d’entretien.

Porter un casque de soudage muni d’un écran de filtre approprié pour pro-

téger votre visage et vos yeux pendant le soudage ou pour regarder (voir

ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

Porter des gants et des vêtements de protection pour

travailler sur un moteur chaud.

Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces

récemment soudées.

Porter des protections approuvés pour les oreilles si le niveau sondre est

trop élevé.

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-

cendie ou une explosion.

Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

Le soudage effectué sur des conteneurs fermés tels que

des réservoirs, tambours ou des conduites peut provoquer

leur éclatement. Des étincelles peuvent être projetées de

LES CHAMPS MAGNÉTIQUES peuvent

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

accidentel de l’électrode avec des objets métalliques peut provoquer des

étincelles, une explosion, un surchauffement ou un incendie. Avant de

commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de

danger.

Porteurs de stimulateur cardiaque, restez à distance.

Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher

des opérations de soudage à l’arc, de gougeage ou

de soudage par points.

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

chaud.

Si des BOUTEILLES sont endomma-

gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous

haute pression. Si une bouteille est endommagée, elle peut

exploser. Du fait que les bouteilles de gaz font normale-

ment partie du procédé de soudage, les manipuler avec

précaution.

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

substances inflammables.

Déplacer toutes les substances inflammables à une distance de 10,7 m de

l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec

des protections homologués.

Des étincelles et des matériaux chauds du soudage peuvent facilement

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

ouvertures.

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

chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des

arcs.

Placer les bouteilles debout en les fixant dans un support stationnaire ou

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

Tenir les bouteilles éloignées des circuits de soudage ou autres circuits

électriques.

Ne jamais placer une torche de soudage sur une bouteille à gaz.

Une électrode de soudage ne doit jamais entrer en contact avec une bou-

teille.

Ne jamais souder une bouteille pressurisée − risque d’explosion.

Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et

raccords convenables pour cette application spécifique; les maintenir ainsi

que les éléments associés en bon état.

Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.

Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation

ou de branchement de la bouteille.

Lire et suivre les instructions concernant les bouteilles de gaz comprimé,

les équipements associés et les publication P-1 CGA énumérées dans les

normes de sécurité.

Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.

Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-

clencher un incendie de l’autre côté.

Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-

voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés

correctement conformément à AWS F4.1 (voir les normes de sécurité).

Brancher le câble sur la pièce le plus près possible de la zone de soudage

pour éviter le transport du courant sur une longue distance par des che-

mins inconnus éventuels en provoquant des risques d’électrocution et

d’incendie.

Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.

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

de ou couper le fil à la pointe de contact.

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

en cuir, une chemise en matériau lourd, des pantalons sans revers, des

chaussures hautes et un couvre chef.

Avant de souder, retirer toute substance combustible de vos poches telles

qu’un allumeur au butane ou des allumettes.

2-3. Dangers existant en relation avec le moteur

LES ACCUMULATIONS DE GAZ ris-

quent de provoquer des blessures ou

même la mort.

L’ACIDE DE LA BATTERIE peut pro-

voquer des brûlures dans les YEUX et

sur la PEAU.

Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

Ne pas renverser la batterie.

Remplacer une batterie endommagée.

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

Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-

rateur d’adduction d’air homologué.

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Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,

L’EXPLOSION DE LA BATTERIE peut

RENDRE AVEUGLE.

débrancher le câble négatif (−) de batterie de la borne.

Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga-

nes mobiles.

Toujours porter une protection faciale, des gants en

caoutchouc et vêtements de protection lors d’une in-

tervention sur la batterie.

Remettre en place les panneaux ou les dipositifs de protection et fermer les

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

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

route accidentelle du moteur.

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

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

REFROIDISSEMENT CHAUD peuvent

provoquer des brûlures.

Ne pas utiliser le poste de soudage pour charger les batteries ou des véhi-

cules de démarrage rapide.

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

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

lieu.

Il est préférable de vérifier le liquide de

refroidissement une fois le moteur refroidi pour éviter

de se brûler.

LE CARBURANT MOTEUR peut pro-

voquer un incendie ou une explosion.

Toujours vérifier le niveau de liquide de refroidissement dans le vase d’ex-

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-

rant ou de faire le plein.

Si le moteur est chaud et que le liquide doit être vérifié, opérer comme sui-

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.

Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-

rant renversé avant de faire démarrer le moteur.

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

d’enlever le bouchon.

LA CHALEUR DU MOTEUR peut pro-

voquer un incendie.

Jeter les chiffons dans un récipient ignifuge.

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

de surfaces inflammables.

DES ORGANES MOBILES peuvent

provoquer des blessures.

Tenir

distance les produits inflammables de

l’échappement.

Ne pas approcher les mains des ventilateurs, cour-

roies et autres pièces en mouvement.

LES ÉTINCELLES À L’ÉCHAPPEMENT

peuvent provoquer un incendie.

Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de

protection.

Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

Utiliser uniquement un pare-étincelles approuvé −

voir codes en vigueur.

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

Demander seulement à un personnel qualifié d’enlever les dispositifs de

sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’en-

tretien et de dépannage.

2-4. Dangers liés à l’air comprimé

Le METAL CHAUD lors du coupage et

gougeage plasma peut provoquer un in-

cendie ou une explosion.

RESPIRER L’AIR COMPRIMÉ peut pro-

voquer des blessures graves ou causer

la mort.

Ne pas utiliser l’air comprimé pour respirer.

Ne pas couper ou gouger à proximité de produits

inflammables.

Utiliser l’air comprimé seulement pour le coupa-

ge, gougeage et les outils pneumatiques.

Surveillez et garder un extincteur à proximité.

L’AIR COMPRIMÉ peut provoquer

des blessures.

DES PIECES CHAUDES peuvent provo-

quer des brûlures et blessures.

Porter des lunettes de sécurité approuvées.

Ne pas toucher le compresseur ou d’autres élé-

ments du circuit air comprimé chauds.

Ne pas diriger le jet d’air vers d’autres ou soi−

même.

Laisser l’ensemble se refroidir avant de toucher

ou d’effectuer la maintenance.

L’AIR COMPRIME EMMAGASINE ET DES

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

changer ou de rajouter des éléments ou avant

d’ouvrir la purge ou le bouchon de remplissage

d’huile.

Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

Arrêter le moteur et relâcher la pression avant

d’effectuer la maintenance.

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

maintenance

Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

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

que les fourches sont suffisamment longues pour dépasser du côté

opposé de l’appareil.

LA CHUTE DE L’APPAREIL peut

blesser.

Utiliser l’anneau de levage uniquement pour soulever

l’appareil lui-même ; sans chariot, de bouteilles de

gaz, remorque, ou autres accessoires.

OM-4406 Page 7

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LE SURCHAUFFEMENT peut endom-

mager le moteur électrique.

LIRE LES INSTRUCTIONS.

Utiliser seulement les pièces de rechange d’origine.

Effectuer la maintenance du moteur et du compres-

seur (si applicable) suivant ce manuel et le manuel du

moteur/compresseur (si applicable).

Arrêter ou déconnecter l’équipement avant de dé-

marrer ou d’arrêter le moteur.

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.

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer

des interférences.

Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a

lieu.

LES ÉTINCELLES VOLANTES ris-

quent de provoquer des blessures.

Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipements

de radio−navigation et de communication, les

services de sécurité et les ordinateurs.

Porter un écran facial pour protéger le visage et les

yeux.

Demander seulement à des personnes qualifiées familiarisées avec des

équipements électroniques de faire fonctionner l’installation.

L’utilisateur est tenu de faire corriger rapidement par un électricien quali-

fié les interférences résultant de l’installation.

Si le FCC signale des interférences, arrêter immédiatement l’appareil.

Effectuer régulièrement le contrôle et l’entretien de l’installation.

Maintenir soigneusement fermés les portes et les panneaux des sources

de haute fréquence, maintenir les éclateurs à une distance correcte et

utiliser une terre et et un blindage pour réduire les interférences

éventuelles.

Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de pro-

tecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque

l’on porte l’équipement homologué de protection du visage, des mains et

du corps.

Les étincelles risquent de causer un incendie − éloigner toute substance

inflammable.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

Laisser l’équipement refroidir ; respecter le facteur de

marche nominal.

Réduire le courant ou le facteur de marche avant de

poursuivre le soudage.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

Ne pas obstruer les passages d’air du poste.

L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique

sensible tel que les ordinateurs et l’équipement com-

mandé par ordinateur tel que les robots.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les

circuits imprimés.

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

électromagnétiquement.

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

ge aussi courts que possible, les grouper, et les poser aussi bas que pos-

sible (ex. par terre).

Veiller à souder à une distance de 100 mètres de tout équipement élec-

tronique sensible.

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

ment à ce mode d’emploi.

En cas d’interférences après avoir pris les mesures précédentes, il in-

combe à l’utilisateur de prendre des mesures supplémentaires telles que

le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil-

tres de ligne ou la pose de protecteurs dans la zone de travail.

Établir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pièces.

Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de

circuits imprimes.

UNE REMORQUE QUI BASCULE peut

entraîner des blessures.

Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.

Installer convenablement le poste sur la remorque

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

l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (télé-

phone : (305) 443−9353, site Web : www.aws.org).

Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à To-

ronto : (416) 747−4044, site Web : www.csa−international.org).

Practice For Occupational And Educational Eye And Face Protection,

norme ANSI Z87.1, de l’American National Standards Institute, 11 West

42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site

Web : www.ansi.org).

Recommended Safe Practices for the Preparation for Welding and Cutting

of Containers and Piping, norme American Welding Society AWS F4.1, de

l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (télé-

phone : (305) 443−9353, site Web : www.aws.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,

norme NFPA 51B, de la National Fire Protection Association, P.O. Box

9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)

770−3000, site Web : www.nfpa.org et www.sparky.org).

National Electrical Code, norme NFPA 70, de la National Fire Protection As-

sociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101

(téléphone: (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de

la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite

1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web :

www.cganet.com).

OSHA, Occupational Safety and Health Standards for General Industry,

Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and

Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent

of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux

régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site

Web : www.osha.gov).

Code for Safety in Welding and Cutting, norme CSA W117.2, de la Cana-

dian Standards Association, Standards Sales, 178 boulevard Rexdale,

2-7. Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnétiques

basse fréquence sur l’organisme

Afin de réduire les champs électromagnétiques en milieu de travail, respec-

ter les consignes suivantes :

En parcourant les câbles de soudage, le courant crée des champs électro-

magnétiques. Les effets potentiels de tels champs restent préoccupants.

Cependant, après avoir examiné plus de 500 études qui ont été faites pen-

dant une période de recherche de 17 ans, un comité de spécialistes du

National Research Council a conclu : « L’accumulation de preuves n’a pas

démontré que l’exposition aux champs magnétiques et aux champs électri-

ques à haute fréquence constitue un risque pour la santé humaine ».

Toutefois, les études et l’examen des preuves se poursuivent. En attendant

les conclusions finales de la recherche, il serait souhaitable de réduire l’ex-

position aux champs électromagnétiques pendant le soudage ou le

coupage.

1. Garder les câbles ensemble en les torsadant ou en les fixant avec du

ruban adhésif.

2. Mettre tous les câbles du côté opposé à l’opérateur.

3. Ne pas s’enrouler les câbles autour du corps.

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

5. Placer la pince de masse le plus près possible de la zone de soudage.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout

consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-

mandé de respecter les consignes ci-dessus.

OM-4406 Page 8

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SECTION 3 − DEFINITIONS

3-1. Warning Label Definitions

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.

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

damagedgloves.

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.

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.

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

watchperson ready to use it.

3.3 Do not weld on drums or any

closed containers.

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

protection.

body

Do not remove or paint over

(cover) the label.

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.

Engine exhaust gases can kill.

7.1 Vent exhaust outside.

7.2 Use unit outside.

3/96

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Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Do not smoke and keep

matches and flames away from

battery.

Sparks can cause battery

gases to explode. Battery

explosion can blind and injure.

Wear a face shield.

Battery acid can burn skin. Do

not spill acid.

+ −

Read Owner’s Manual.

Wear rubber gloves.

Dead battery

−

Engine block

Fully charged battery

10 Do not connect last negative

cable to dead battery − connect

instead to engine block.

−

11 Jumper cables

−

observe

polarity and make connections

in numbered sequence shown.

S-176 108

12 Once dead battery is charged,

disconnect cables in sequence

3/96

shown.

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Moving parts, such as fans,

rotors, and belts, can cut

fingers and hands and cause

injury. Keep away from moving

parts.

3/96

S-176 106

StartingAid Switch. Below 32°F (0°C),

push switch up for 60 seconds before

starting engine.

Starting Instructions:

Press and hold Magnetic

Shutdown switch.

Turn Engine Control switch to

Start position.

Release Engine Control switch

and Starting Aid switch (if used)

when engine starts.

Continue holding

Shutdown switch for 3 seconds

after engine starts.

Magnetic

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OM-4406 Page 10

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Hot muffler and exhaust pipes

can cause severe burns. Do

not touch hot muffler or pipes.

S-176 230

3/96

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Falling equipment can cause

serious injury and damage.

Use lifting eye to lift or move

unit

only.

Use

proper

equipmentwhen lifting.

Do not use lifting eye to lift and

support unit and trailer or other

heavy devices or accessories.

S-176 104

3/96

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OM-4406 Page 11

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Fire hazard from leaking

enginefuel. Fire can result from

welding

base

non-designatedareas causing

a possible fuel leak.

Fuel tank is located inside

base.

Do not weld on base of unit.

Weld only on supplied brackets

or bolt unit down.

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Electric shock from wiring can

kill.

Moving parts, such as fans,

rotors, and belts, can cut

fingers and hands and cause

injury. Keep away from moving

parts.

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OM-4406 Page 12

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Remove unit from shipping

crate. Remove Owner’s

Manual from unit. Follow

instructions to install muffler.

S-177 571

Read Owner’s Manual. Read

labels on unit.

Use Diesel Fuel only, and fill

fuel tank. Leave room for

expansion.

Warning! Watch Out! There

are possible hazards as

shown by the symbols. Read

Owner’s Manual. Follow

instructions to activate

battery.

DIESEL

Check oil level. Add oil if

necessary.

During the first 50 hours of

operation, keep welding load

above 200 amperes. Do not

weld below 200 amperes of

output.

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 For CE Products

CC Models

CC/CV Models

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3-3. Symbols And Definitions

Some symbols are found only on CE products.

NOTE

Fast (Run, Weld/

Power)

Stop Engine

Starting Aid

Slow (Idle)

Start Engine

Engine Oil

Pressure

Battery (Engine)

Check Injectors/

Pump

Check Valve

Clearance

Protective Earth

(Ground)

Fuel

Certified/Trained

Mechanic

Positive

Negative

Volts

Welding Arc

Remote

Amperes

Panel/Local

Output

A V

Air Temperature Or

Engine

Alternating

Current

Engine

Temperature

Stick (SMAW)

Welding

Constant Current

(CC)

MIG (GMAW)

Welding

TIG (GTAW)

Single Phase

Time

Hours

Seconds

Read Operator’s

Manual

Do Not Switch

While Welding

Three Phase

Circuit Breaker

Engine-Driven,

Three-Phase

Alternator With

Rectifier

Electrode

Connection

Work Connection

Hertz

Rated No Load

Conventional

Load Voltage

Rated Load

Speed

Duty Cycle

U₀

n₀

U₂

Voltage (Average)

I₂

Rated Idle

Speed

Rated No Load

Speed

Rated Welding

Current

n₁

Contactor On

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OM-4406 Page 14

SECTION 4 − SPECIFICATIONS

4-1. Weld, Power, And Engine Specifications

Maximum

Open-

Welding

Mode

Weld Output

Range

Rated Welding

Output

Generator Power

Rating

Fuel

Capacity

Engine

Circuit

Voltage

Standard

Single-Phase,

4 kVA/kW, 34/17 A,

120/240 V AC,

50/60 Hz

45 − 500 A

(CC Models)

CC/DC

300 A, 40 Volts DC,

100% Duty Cycle

15 − 500 A

(CC/CV Models)

400 A, 40 Volts DC,

60% Duty Cycle

25 gal

(95 L)

Three-Phase Generator

Option*

Single-Phase/Three-Phase,

12/15 kVA/kW, 50/36A,

120/240 VAC, 60 Hz

Caterpillar 3024C

Water-Cooled,

CV/DC

500 A, 30 Volts DC,

40% Duty Cycle

Four-Cylinder,

(CC/CV

Models

Only)

14 − 40 V

32.8 HP Diesel Engine

*In Addition To Standard

4 kVA/kW Generator Power

4-2. Dimensions, Weights, And Operating Angles

Dimensions

60 in (1524 mm)

Height

(to top of exhaust)

28-1/2 in (724 mm)

(mtg. brackets turned in)

Do not exceed tilt angles or engine could

be damaged or unit could tip.

Width

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)

56 in (1422 mm)

46-1/2 in (1181)

9-5/8 in (244 mm)

27-1/2 in (699 mm)

1 in (25 mm)

30°

29-1/2 in (743 mm)

30°

20°

9/16 in (14 mm) Dia.

4 Holes

Front Panel End

With mounting brackets in center

position. Dimensions vary with

location of mounting brackets.

Weight

802 161-A

No fuel: 1545 lb (701 kg)

w/fuel: 1720 lb (780 kg)

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OM-4406 Page 15

4-3. Volt-Ampere Curves For CC Models

The volt-ampere curve shows the

minimum and maximum voltage

and amperage output capabilities of

the welding generator. Curves of all

other settings fall between the

curves shown.

100

Ranges

210 − Max

165 − 350

100 − 250

65 − 120

45 − 85

100

200

300

400

500

600

700

DC AMPERES

202 666-A

Notes

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OM-4406 Page 16

4-4. Volt-Ampere Curves For CC/CV 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.

A. Stick Mode

100

Ranges

Max

150 − 420

110 − 315

75 − 200

40 − 90

100

200

300

400

500

600

700

800

900

DC AMPERES

B. MIG Mode

100

MAX

MIN

100 200 300 400 500 600 700 800 900 1000

DC AMPERES

C. TIG Mode

100

Ranges

50 − 335

40 − 240

25 − 150

15 − 75

100 150 200 250 300 350 400 450 500

DC AMPERES

202 655 / 202 656 / 202 654

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4-5. Fuel Consumption

The curve shows typical fuel use

under weld or power loads.

2.00

1.75

1.50

1.25

1.00

0.75

0.50

0.25

0.00

IDLE

100

150

200

250

300

350

400

DC WELD AMPERES AT 100% DUTY CYCLE

199 032

4-6. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

100% Duty Cycle At 300 Amperes

Exceeding duty cycle can

damage unit and void

warranty.

ContinuousWelding

% DUTY CYCLE

199 140

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OM-4406 Page 18

4-7. AC Generator Power Curve

The ac power curve shows the gen-

erator power in amperes available

at the 120 and 240 volt receptacles.

150 300

125 250

100 200

75 150

50 100

25 50

AC AMPERES IN 240V MODE

20 30 40

AC AMPERES IN 120V MODE

193 018

4-8. Optional Three-Phase Generator Curves

The ac power curves show the gen-

erator power available in amperes

at the single-phase 120/240 volt re-

ceptacle or three-phase 240 volt

terminals.

A. 12 kVA/kW Single-Phase AC Output (No Weld Load)

280

260

240

220

200

180

100

AC AMPERES

B. 15 kVA/kW Three-Phase AC Output (No Weld Load)

280

260

240

220

200

180

AC AMPERES

198 868 / 198 869

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4-9. Volt-Ampere Curve For CC/CV Models In AC TIG Mode

. AC output is only available on

units equipped with optional

Polarity/AC switch.

The volt-ampere curve shows the

minimum and maximum voltage

and amperage output capabilities of

the welding generator. Curves of all

other settings fall between the

curves shown.

100

Ranges

55 − 350

35 − 205

25 − 105

15 − 45

100 150 200 250 300 350 400 450 500

AC AMPERES

207 045

Notes

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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-

ble codes.

Movement

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

extension cord.

formation.

Grounding:

Equipment Grounding Terminal

(On Front Panel)

Location

Grounding Cable (Not Supplied)

Metal Vehicle Frame

Connect cable from equipment

ground terminal to metal vehicle

frame. Use #10 AWG or larger insu-

lated copper wire.

Grounding

GND/PE

Electrically bond generator frame to

vehicle frame by metal-to-metal contact.

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

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

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

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5-2. Using Lifting Eye

Lifting Eye

Nut

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

carriage bolt through slot in bracket

and secure with nut (bolt and nut not

supplied).

Tools Needed:

Ref. 802 311

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

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OM-4406 Page 22

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-

quately support unit and pre-

vent damage to base.

Mounting Surface:

Cross-Supports

Mounting Brackets (Supplied)

Mount unit on flat surface or use

cross-supports to support base.

Secure unit with mounting brack-

ets.

1/2 in Bolt And Washer

(Minimum − Not Supplied)

Inadequate support.

3/8-16 x 1 in Screws

(Supplied)

To Bolt Unit In Place:

Do not use flexible mounts.

Remove hardware securing the

four mounting brackets to the base.

Reverse brackets and reattach to

base with original hardware.

Mount unit to truck or trailer with 1/2

in (12 mm) or larger hardware (not

supplied).

Using Mounting Brackets

To Weld Unit In Place:

Weld unit to truck or trailer only at

the four mounting brackets.

Welding Unit In Place

Bolting Unit In Place

Tools Needed:

9/16 in

install3 5/02 803 274 / 190 250-A / 803 231 / 802 311

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5-4. Installing Exhaust Pipe

Stop engine and let cool.

rection but always away from front

panel and direction of travel.

Tools Needed:

1/2 in

Ref. 802 311 / Ref. 201 841

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

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

Remove battery from unit.

Eye Protection − Safety

Glasses Or Face Shield

Rubber Gloves

Vent Caps

Sulfuric Acid Electrolyte

(1.265 Specific Gravity)

Well

Fill each cell with electrolyte to

bottom of well (maximum).

Do not overfill battery cells.

Wait ten minutes and check electro-

lyte level. If necessary, add electro-

lyte to raise to proper level. Reins-

tall vent caps.

Battery Charger

Read and follow all instruc-

tions supplied with battery

charger.

Charge battery for 12 minutes at 30

amperes or 30 minutes at 5 am-

peres. Disconnect charging cables

and install battery.

. When electrolyte is low, add

only distilled water to cells to

maintainproper level.

5 A For 30 Minutes

Tools Needed:

−

rubber gloves

30 A For 12 Minutes

glasses

drybatt1 1/98 − 0886

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5-6. Connecting The Battery

Connect Negative (−) Cable Last.

−

Tools Needed:

1/2 in

802 168-B / Ref. 201 841 / 802 313 / S-0756-C

Notes

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5-7. Engine Prestart Checks

Check radiator coolant

level when fluid is low in

recovery tank.

Full

Capacity:

9.5 qt (9.01L)

Full

Diesel

Full

Coolant Recovery Tank

Hot Full

Cold Full

802 490

Do not run out of fuel or air will enter fuel sys-

tem and cause starting problems. See en-

gine manual to bleed air from fuel system.

freeze to mixture if using the unit in tempera-

tures below −34° F (−37° C).

Keep radiator and air intake clean and free

of dirt.

. Check all engine fluids daily.

Engine must be cold and on a level surface.

Unit is shipped with 20W break-in oil.

Automaticshutdown system stops engine if

oil pressure is too low or coolant tempera-

ture is too high.

Oil

After fueling, check oil with unit on level sur-

face. If oil is not up to full mark on dipstick,

add oil (see maintenance label).

Incorrect engine temperature can

damage engine. Do not run engine

without a properly working thermo-

stat and radiator cap.

. This unit has a low oil pressure shut-

down switch. However, some condi-

tions may cause engine damage before

the engine shuts down. Check oil level

often and do not use the oil pressure

shutdown system to monitor oil level.

Follow run-in procedure in engine manual.

If unburned fuel and oil collect in exhaust

pipe during run-in, see Section 11.

Coolant

Check coolant level in radiator before start-

ing unit the first time. If necessary, add cool-

ant to radiator until coolant level is at bottom

of filler neck.

Use Starting Aid switch (see Section

6-1 or 7-1).

Keep battery in good condition. Store

battery in warm area off concrete sur-

face.

Check coolant level in recovery tank daily.

If necessary, add coolant to recovery tank

until coolant level is between Cold Full and

Hot Full levels. If recovery tank coolant level

was low, also check coolant level in radiator.

Add coolant if level is below bottom of radia-

tor filler neck.

Fuel

Do not use gasoline. Gasoline will

damage engine.

Use fuel formulated for cold weather

(diesel fuel can gel in cold weather).

Contact local fuel supplier for fuel in-

formation.

The unit is shipped with enough fuel to pre-

vent air from entering fuel system. Add fresh

diesel fuel before starting (see engine main-

tenance label for fuel specifications). Leave

filler neck empty to allow room for

expansion.

Unit is shipped with an engine coolant mix-

ture of water and ethylene glycol base anti-

^{freeze rated to −34}° F (−37° C). Add anti-

Use correct grade oil for cold weather

(see Section 9-1).

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5-8. Connecting To Weld Output Terminals

Stop engine.

Tools Needed:

3/4 in

Positive (+) Weld Output Terminal

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 op-

tional 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

Electrode Positive (DCEP) on CC/CV models,

connect wire feeder cable to Positive (+) termi-

nal on left and work cable to Negative (−) ter-

minal on right. Use Process/Contactor switch

to select type of weld output (see Section 7-3).

For Direct Current Electrode Negative

(DCEN), reverse cable connections.

If equipped with optional Polarity switch or op-

tional Polarity/AC switch, connect wire feeder

cable to Electrode (+) terminal on left and

work cable to Work (−) terminal on right.

802 311

5-9. Selecting Weld Cable Sizes*

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

Not Exceeding***

150 ft

(45 m)

200 ft

250 ft

300 ft

350 ft

400 ft

100 ft (30 m) or Less

(60 m) (70 m) (90 m) (105 m) (120 m)

Weld Output

Terminals

Stop engine before

connectingto weld out-

put terminals.

10 − 60% 60 − 100%

Welding

Amperes

Duty

10 − 100% Duty Cycle

Cycle

Do not use worn, dam-

aged, undersized, or

poorly spliced cables.

100

150

200

4 (20)

3 (30)

4 (20)

3 (30)

2 (35)

4 (20)

2 (35)

1 (50)

3 (30)

1 (50)

2 (35)

1/0 (60)

2/0 (70)

1 (50)

1/0 (60)

3/0 (95)

1/0 (60)

3/0 (95)

2/0 (70)

1/0 (60)

3/0 (95) 4/0 (120) 4/0 (120)

2 ea. 2/0 2 ea. 2/0

250

300

350

400

500

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2/0 (70)

3/0 (95) 4/0 (120)

(2x70)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

(2x70) (2x95) (2x95)

1/0 (60)

2/0 (70)

3/0 (95)

3/0 (95) 4/0 (120)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

(2x70) (2x95) (2x95) (2x120)

1/0 (60)

2/0 (70)

4/0 (120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

(2x70) (2x95) (2x120) (2x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0

(2x70) (2x95) (2x120) (3x95) (3x95)

* This chart 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.

( ) = mm for metric use

S-0007-E−

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

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5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models

Remote Amperage Adjust

Receptacle RC13

Connect optional remote control to

RC13 (see Section 6-3).

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

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

Socket*

Socket Information

24 volts ac. Protected by circuit

breaker CB5.

24 VOLTS AC

Contact closure to A completes

24 volt ac contactor control

circuit.

Output to remote control:+10

volts dc in MIG or Stick mode;

0 to +10 volts dc in TIG mode.

Remote control circuit common.

New! LDR-14 long

distance remote

(includes 120 V

receptacle)

REMOTE

OUTPUT

CONTROL

DC input command signal: 0 to

+10 volts from min. to max. of

remote control with Voltage/

Amperage Adjust control at

max.

115 volts, 10 amperes, 60 Hz

ac. Protected by circuit breaker

CB6.

115 VOLTS AC

Contact closure to I completes

115 volt ac contactor control

circuit.

Chassis common.

GND

802 311

NEUTRAL

Circuit common for 24 and 115

volt ac circuit.

*The remaining sockets are not used.

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SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS

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

10 11

201 841 / 802 311

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

Engine Starting Controls

Magnetic Shutdown Switch

Use switch during start-up to bypass engine

shutdown system. System stops engine if oil

pressure is too low or coolant temperature is

too high.

is below 5 psi (34 kPa). Light goes on momen- 13 Ampere Range Switch

tarily during start-up but goes out when en-

gine reaches normal oil pressure.

Do not switch under load.

Use switch to select weld amperage range.

For most welding applications, use lowest

amperagerange possible to help prevent arc

outages.

Stop engine and fix trouble if Engine

Oil Pressure light stays on after start-

up.

Fuel Light

Starting Aid Switch

14 AmperageAdjust Control

Light is not active on this model.

Engine Hour Meter

Engine Gauges

Use switch to energize starting aid for cold

weather starting (see starting instructions fol-

lowing).

Control adjusts amperage within range se-

lected by Ampere Range switch. Weld output

would be about 153 A DC with controls set as

shown (50% of 100 to 205 A).

Engine Control Switch

. To read gauges and engine indicator

lights with engine off, turn Engine Control

switch to Run/Idle and press Magnetic

Shutdown switch (see Section 9-9).

Use switch to start engine, select engine

speed (if unit has auto idle option), and stop

engine.

In Run position, engine runs at weld/power

speed. In Run/Idle position (optional), engine

. The numbers around the control are for

reference only and do not represent an

actual percentage value.

15 Stick/TIG Selection Switch

Fuel Gauge

Use switch to disable the max OCV circuit

and the arc drive (dig) circuit for scratch start

TIG welding (see max OCV note under Weld

Controls).

When switch is in the Stick position, the max

OCV circuit resets Amperage Adjust Control

R1 to maximum when the arc breaks.

Also in the Stick position, the arc drive (dig)

circuit provides additional amperage during

low voltage (short arc length conditions) to

prevent “sticking” electrodes.

When switch is in Scratch Start TIG position,

the max OCV and arc drive (dig) circuits are

disabled and OCV changes when the control

is adjusted.

runs at idle speed at no load and weld speed Use gauge to check fuel level.

with load applied.

To check fuel level when engine is not run-

To Start:

ning, turn Engine Control switch to Run/Idle

position and press Magnetic Shutdown

switch.

Do not use ether.

. If engine does not start, let engine come

to a complete stop before attempting re-

start.

Above 325 F (05 C): turn Engine Control

switch to Start while pressing Shutdown

switch. Release Engine Control switch when

engine starts. Continue holding Shutdown

switch until engine indicator lights go out.

Below 325 F (05 C): turn engine control switch

to Run/Idle position. Push Starting Aid switch

up for 60 seconds. While still holding Starting

Aid switch, press Magnetic Shutdown switch

and turn Engine Control switch to Start. Re-

lease Engine Control switch and Starting Aid

switch when engine starts. Continue holding

Shutdown switch until engine indicator lights

go out.

10 Battery Voltmeter (Optional)

Use gauge to check battery voltage and moni-

tor the engine charging system. The meter

should read about 14 volts dc when the en-

gine is running, and about 12 volts dc when

the engine is stopped.

11 Engine Coolant Temperature Gauge

(Optional)

Normal temperature is 180 - 203° F (82 - 95°

C). When equipped with gauge option, engine

stops if temperature exceeds 220° F (104° C).

16 Amperage Adjust Switch And Remote

Amperage Adjust Receptacle

12 Engine Oil Pressure Gauge (Optional)

Connect optional remote control to RC13

(See Section 5-10). Use switch to select front

panel or remote amperage control. For re-

mote control, place switch in Remote position

and connect remote control to Remote Am-

perage Adjust receptacle RC13 (see Sec-

tions 5-10 and 6-3).

Normal pressure is 30 − 60 psi (207 − 414

kPa). When equipped with gauge option, en-

gine stops if pressure is below 10 psi (69

kPa).

To Stop: turn Engine Control switch to Off

position.

Engine Indicator Lights

Weld Controls

17 Polarity Switch (Optional)

a max OCV control circuit that resets Am-

perage Adjust control R1 to maximum

when the arc breaks. When an arc is

struck, weld output control returns to the

R1 front panel or combination front panel/

remote control setting. The Amperage

Adjust control adjusts amperage only

when welding and does not adjust open-

circuit voltage.

Do not switch under load.

Battery Charging Light

Light goes on if engine alternator is not charg-

ing battery. Engine continues to run.

Use switch to change weld output. Select ei-

ther DC Electrode Positive (DCEP) or DC

Electrode Negative (DCEN).

Weld Meters

18 DC Voltmeter (Optional)

Voltmeterdisplays voltage at the weld output

terminals, but not necessarily the welding arc

due to resistance of cable and connections.

Stop engine and fix trouble if Battery

Charging light goes on.

Engine Temperature Light

Light goes on and engine stops if engine tem-

perature is above 221 ° F (105° C).

Stop engine and fix trouble if Engine

Temperature light goes on.

Engine Oil Pressure Light

The max OCV circuit is disabled when

the Stick/TIG Selection switch is in

Scratch Start TIG position (see item 15). Ammeter displays amperage output of the

19 DC Ammeter (Optional)

Light goes on and engine stops if oil pressure

unit.

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6-3. Remote Amperage Control On CC Models (Optional)

Remote Amperage Adjust

Receptacle RC13

Connect optional remote control to

RC13 (see Section 5-10).

In Example:

Range = 100 to 205 A DC

Example: Combination Remote Amperage Control (Stick)

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

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

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Notes

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SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS

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

10 11

201 579 / 802 311-D

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

Engine Starting Controls

Magnetic Shutdown Switch

Oil Pressure light stays on after start- 15 Voltage/AmperageAdjust Control

up.

With Process/Contactor switch in any Stick or

TIG setting, use control to adjust amperage

within range selected by Ampere Range

switch. With Process/Contactor switch in any

MIG position, use control to adjust voltage.

With Voltage/Amperage Adjust Switch in Re-

mote position, control limits the remote am-

Fuel Light

Light is not active on this model.

Engine Hour Meter

Engine Gauges

Use switch during start-up to bypass engine

shutdown system. System stops engine if oil

pressure is too low or engine temperature is

too high.

Starting Aid Switch

Use switch to energize starting aid for cold

weather starting (see starting instructions fol-

lowing).

and MIG modes.

lights with engine off, turn Engine Control

switch to Run/Idle and press Magnetic

Shutdown switch (see Section 9-9).

Weld output would be about 213 A DC with

controls set as shown (50% of 110 to 315 A).

Engine Control Switch

Use switch to start engine, select engine

speed ( if unit has auto idle option), and stop

engine.

Fuel Gauge

. The numbers around the control are for

reference only and do not represent an

actual percentage value.

Use gauge to check fuel level.

To check fuel level when engine is not run-

ning, turn Engine Control switch to Run/Idle

position and press Magnetic Shutdown

switch.

In Run position, engine runs at weld/power

speed. In Run/Idle position (optional), engine

runs at idle speed at no load and weld speed

with load applied.

16 Voltage/Amperage Adjust Switch And

Remote 14 Receptacle

Use switch to select front panel or remote

voltage/amperage control. For remote con-

trol, place switch in Remote position and con-

nect remote control to Remote 14 receptacle

RC14 (see Sections 5-11 and 7-4).

10 Battery Voltmeter (Optional)

To Start:

Use gauge to check battery voltage and moni-

tor the engine charging system. The meter

Do not use ether.

17 Polarity Switch (Optional)

gine is running, and about 12 volts dc when

the engine is stopped.

to a complete stop before attempting re-

start.

Do not switch under load.

Above 325 F (05 C): turn Engine Control

switch to Start while pressing Shutdown

switch. Release Engine Control switch when

engine starts. Continue holding Shutdown

switch until engine indicator lights go out.

11 Engine Coolant Temperature Gauge

(Optional)

Use the Polarity switch to change weld out-

put. Select either DC Electrode Positive

(DCEP) or DC Electrode Negative (DCEN).

Normal temperature is 180 - 203° F (82 - 95°

C). When equipped with gauge option, engine

stops if temperature exceeds 220° F (104° C).

18 Polarity/AC Switch (Optional)

Electric shock can kill.

Below 325 F (05 C): turn engine control switch

to Run/Idle position. Push Starting Aid switch

up for 60 seconds. While still holding Starting

Aid switch, press Magnetic Shutdown switch

and turn Engine Control switch to Start. Re-

lease Engine Control switch and Starting Aid

switch when engine starts. Continue holding

Shutdown switch until engine indicator lights

go out.

12 Engine Oil Pressure Gauge (Optional)

Do not use AC output in damp areas,

if movement is confined, or if there is

a danger of falling.

Normal pressure is 30 − 60 psi (207 − 414

kPa). When equipped with gauge option, en-

gine stops if pressure is below 10 psi (69

kPa).

Use AC output ONLY if required for the

welding process. If AC output is re-

quired, use remote output control if

present on unit.

Weld Controls

13 Process/Contactor Switch

Do not switch under load.

See Section 7-3 for Process/Contactor

switch information.

To Stop: turn Engine Control switch to Off

position.

Use Polarity/AC switch to select AC or DC

weld output and DC weld output polarity. For

Direct Current Electrode Negative (DCEN),

turn switch to − (Negative) position. For Direct

Current Electrode Positive (DCEP), turn

switch to + (Positive) position. For weld pro-

cesses that require alternating current (AC),

use AC position.

14 Ampere Range Switch

Engine Indicator Lights

Do not switch under load.

Battery Charging Light

Light goes on if engine alternator is not charg-

ing battery. Engine continues to run.

Use switch to select weld amperage range.

Use the lowest four ranges for Stick and TIG

welding. Read the upper set of numbers at

each range for Stick welding and the lower set

at each range for TIG welding.

Stop engine and fix trouble if Battery

Charging light goes on.

Weld Meters

Engine Temperature Light

. Optional weld meters do not work with

optional Polarity/AC switch in AC

position.

Light goes on and engine stops if engine tem-

Use the highest range for MIG welding and for

cutting and gouging (CAC-A).

perature is above 221 ° F (105° C).

Stop engine and fix trouble if Engine

Temperature light goes on.

For most welding applications, use lowest

amperagerange possible to help prevent arc

outages.

19 DC Voltmeter (Optional)

Voltmeterdisplays voltage at the weld output

terminals, but not necessarily the welding arc

due to resistance of cable and connections.

Engine Oil Pressure Light

Light goes on and engine stops if oil pressure

is below 5 psi (34 kPa). Light goes on momen-

tarily during start-up but goes out when en-

gine reaches normal oil pressure.

20 DC Ammeter (Optional)

Ammeter displays amperage output of the

unit.

Stop engine and fix trouble if Engine

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7-3. Process/Contactor Switch On CC/CV Models

Process/Contactor Switch

Weld output terminals are ener-

gized when Process/Contactor

switch is in an Electrode Hot posi-

tion and the engine is 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 en-

gine 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 am-

perage 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 Section 8-2).

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

Device, Or Remote Control

Remote − TIG

At Remote 14 Receptacle

Not Active

Remote − Stick

Remote − MIG

Stick (SMAW) With Remote On/Off

MIG (GMAW)

At Remote 14 Receptacle

Electrode Hot

Active

Electrode Hot − MIG

MIG (GMAW)

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting

And Gouging

Electrode Hot − Stick

Electrode Hot

Active

Electrode Hot − Scratch

Scratch Start TIG (GTAW)

Start TIG

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OM-4406 Page 36

7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)

Remote 14 Receptacle RC14

Connect optional remote control to

RC14 (see Section 5-11).

In Example:

Process = Stick (Using Remote On/Off)

Range = 110 to 315 A DC

Min = 110 A DC

Example: Combination Remote Amperage Control (Stick)

Max = 315 A DC

Max (315 A DC)

Min (110 A DC)

Set Remote

Process

Set V/A

Adjust Switch

Set Range

Control Not

Used In Remote

Stick Mode

Adjust Optional Remote Control

In Example:

Process = TIG (Using Remote On/Off)

Range = 40 to 240 A DC

Example: Combination Remote Amperage Control (TIG)

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 Remote

Process

Set V/A

Adjust Switch

Set Range

Set Control

Adjust Optional Remote Control

0774 / Ref. 201 579 / 802 169-E

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OM-4406 Page 37

SECTION 8 − OPERATING AUXILIARY EQUIPMENT

8-1. 120 Volt And 240 Volt Receptacles

120 V 20 A AC GFCI

Receptacle GFCI1

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

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

is working properly.

Circuit Breaker CB1

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.

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

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OM-4406 Page 38

8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)

in Electrode Hot - Stick position

when using three−phase genera-

tor (see Section 7-3).

Single-Phase Power Connection

Single-Phase Generator Power

120/240 V 50 A Receptacle

RC5

RC5 is connected to the optional

three−phasegenerator 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.

Circuit Breaker CB7

Circuit breaker CB7 protects single-

phase receptacle RC5 and the load

wires from overload. If CB7 opens, all

three−phasegenerator output stops

and the receptacle does not work.

Three-Phase Generator Power

Three-Phase Power Connection

Single

Phase

Three

Phase

Stop engine.

Output

Power and weld outputs are

live at the same time. Discon-

nect or insulate unused

cables.

Volts

120/240

240

Close panel opening

if no connections are

made to generator.

Amps

KVA/KW

. Have qualified person install ac-

cording to circuit diagram and

Generator Power Guidelines

(see Section 12).

Frequency

Engine Speed

60 Hz

1850 RPM

Lead 42 connects to GROUND stud on

front of unit.

Jumper 42 is connected to 90 at factory.

Remove generator power panel

mountingscrews. Tilt panel forward.

Lead 93

Lead 92

Lead 91

Remove plug

before inserting

leads. Reinstall

bushing.

Lead 42 (Circuit Grounding

Lead)

Lead 90 (Neutral)

Rear Of Panel

Isolated Neutral Terminal

Jumper Lead 42

10 Grounding Terminal

Jumper 42 is connected to lead 90 at

factory. Jumper 42 may be discon-

nected from neutral to meet applica-

ble electrical codes.

Lead 42 connects to front panel

Ground stud.

11 User-Supplied Leads

12 Circuit Breaker CB7 User

Terminals

Connect user-supplied leads to ter-

minals on CB7 and to the isolated

neutral terminal and grounding termi-

nal as necessary.

panel

opening if no

connections

are made to

generator.

. Circuit breaker CB7 protects

single-phase receptacle RC5

and the load wires from overload.

If CB7 opens, all three−phase

generator output stops and the

receptacle does not work.

240V

120V

1-Phase

3-Phase

120V

Tools Needed:

240V

Reinstall generator power panel.

240V

Ref. 197 399 / 802 332-E

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OM-4406 Page 39

8-3. Optional Generator Power Receptacles

120 V 20 A AC GFCI

Receptacle GFCI1

240 V 16 A AC European

Receptacle RC1

European Receptacle

240 V 15 A AC Australian

Receptacle RC1

240 V 15 A AC South African

Receptacle RC1

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.

gine at weld/power speed and

press test button to verify GFCI

is working properly.

Australian Receptacle

Circuit Breaker CB2

Circuit Breaker CB3

CB2 protects GFCI1 from overload.

If CB2 opens, GFCI1 does not

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.

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.

South African Receptacle

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

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OM-4406 Page 40

SECTION 9 − MAINTENANCE & TROUBLESHOOTING

9-1. Maintenance Label

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9-2. Routine Maintenance

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

extended period.

Note

Stop engine before maintaining.

Recycle engine

fluids.

Label for important start-up, service,

and storage information. Service unit

more often if used in severe conditions.

To be done by Factory Authorized

Service Agent.

Every 8 h

Coolant

Full

FUEL

WATER

Wipe

Spills.

Check Fluid

Levels. See

Section 5-7.

Drain Water

From Fuel

System.

OIL

Full

Every 50 h

Clean And

Tighten

Clean Air Filter.

See Section 9-4.

Weld

Terminals.

Every 100 h

Clean And

Tighten

Check air cleaner

hoses for cracks

and loose clamps.

Battery

Connections.

Every 250 h

Check Belt

Tension.

Replace

Unreadable

Labels.

1/2 in.

(13 mm)

Check And

Clean Spark

Arrestor. See

Section 9-5.

Change Oil Filter.

See Section 9-7.

Change Oil. See

Section 9-7.

Every 500 h

Repair Or

Replace

Damaged

Cables.

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OM-4406 Page 42

Every 1000 h

Change Fuel

Filters. See

Section 9-7.

Check Radiator

Fluid Level. See

Section 5-7.

Blow Out Or

Vacuum Inside.

During Heavy

Service,

Service Welding

Generator Brushes And

Slip Rings. Service More

Often In Dirty Conditions.*

Clean Monthly.

Check

Valve

Clearance.*

Drain Sludge

From Fuel

FUEL

SLUDGE

Tank. See

Section 9-7.

Every 2000 h

Clean/Set Injectors.*

9-3. Caterpillar Customer Assistance

Service

When a problem arises concerning the

operation or service of the engine, the

problemwill normally be managed by the

dealer in your area.

Your satisfaction is a primary concern to

Caterpillar and to Caterpillar dealers. If

you have a problem that has not been

handledto your complete satisfaction, fol-

low these steps:

Discuss your problem with a

manager from the dealership.

If your problem cannot be resolved

at the dealer level without additional

assistance, call a Field Service

Coordinator at 1-800-447-4986.

If your needs still have not been

met, submit the matter in writing to:

Caterpillar Inc.

Manager, Customer Service,

Engine Division

Mossville Bldg A

P.O. Box 600

Peoria, IL 61552-0600

Please follow the above steps in se-

quence if a problem arises.

Website Address

www.caterpilla r .com

Altitude

Contact the Caterpillar applications de-

partment for information on the effect of

ambient conditions on Caterpillar 3024

engines.

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OM-4406 Page 43

9-4. Servicing Air Cleaner

Stop engine.

Do not run engine without air

cleaner or with dirty element. En-

gine damage caused by using a

damaged element is not covered

by the warranty.

be cleaned but the dirt holding capac-

ity of the filter is reduced with each

cleaning. The chance of dirt reaching

the clean side of the filter while clean-

ing and the possibility of filter damage

makes cleaning a risk. Consider the

risk of unwarrantable equipment

damage when determining whether

to clean or replace the primary ele-

ment.

Optional

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

2 in (51 mm)

from element.

Housing

Safety Element (Optional)

Primary Element

Dust Cap

Dust Ejector

To clean air filter:

Wipe off cap and housing. Remove cap

and dump out dust. Remove element(s).

Wipe dust from inside cap and housing

with damp cloth. Reinstall safety element

(if present). Reinstall cap.

Blow

Inspect

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 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 201 841

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9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler

Stop engine and let cool.

Spark Arrestor Muffler

Cleanout Plug

Remove plug and remove any dirt

covering cleanout hole.

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.

Reinstall cleanout plug.

Tools Needed:

3/8 in

Ref. 802 311 / Ref. 802 160 / Ref. 201 841

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OM-4406 Page 45

9-6. Adjusting Engine Speed

After tuning engine, check engine

speed with tachometer or frequen-

cy meter. See table for proper no

load speed. If necessary, adjust

speed as follows:

Engine Speed

(No Load)

1850 rpm max

(61.6 Hz)

Start engine and run until warm.

1250 rpm

(41.6 Hz)

On CC models, place Stick/TIG

switch in Stick position.

On CC/CV models, turn Process/

Contactor switch to Stick − Elec-

trode Hot position.

Idle Speed Adjustment

Throttle Rod/Plunger

Locknut

Loosen locknut. Place Engine Con-

trol switch in Run/Idle position.

Turn throttle rod and plunger until

engine runs at idle speed. Tighten

locknut.

. Be sure solenoid plunger pulls

all the way in (“bottoms”) when

energized.

. If necessary, move linkage to

other hole in bracket or move

cotter pin to other hole in throttle

arm to set idle speed correctly.

Weld/Power Speed Adjustment

Engine Weld/Power Speed

Adjustment Screw

Locknut

Place Engine Control switch in Run

position.

Loosen locknut. Turn screw until

engine runs at weld/power speed.

Tighten locknut.

than specified.

Stop engine.

If necessary, move

linkage to other hole in

bracket or move cotter

pin to other hole in

throttle arm to set idle

speed correctly.

802 490 / 802 538-A

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OM-4406 Page 46

9-7. Servicing Fuel And Lubrication Systems

Stop engine and let cool.

After servicing, start engine

and check for fuel leaks.

Stop engine, tighten connec-

tions as necessary, and wipe

up spilled fuel.

Oil Filter

Oil Drain Valve And Hose

Oil Fill Cap

Fuel Line

Primary Fuel Filter (Fuel/

Water Separator)

Petcock

Secondary Fuel Filter

Fuel Tank Sludge Drain Valve

To change oil and filter:

Route oil drain hose and valve

through hole in base. See engine

manual and engine maintenance

label for oil/filter change in-

formation.

To drain water from fuel system:

Open primary fuel filter petcock and

drain water into metal container.

Close petcock when water-free fuel

flows.

To replace primary fuel filter:

Turn filter counterclockwise. Re-

move filter.

Fill new filter with fresh fuel. Apply

thin coat of fuel to gasket on new fil-

ter. Install new filter and turn clock-

wise. Bleed air from fuel system ac-

cording to engine manual.

Inspect fuel lines, and replace if

cracked or worn.

To replace secondary fuel filter:

See engine manual.

To drain sludge from fuel tank:

Beware of fire. Do not smoke

and keep sparks and flames

away from drained fuel. Dis-

pose of drained fuel in an en-

vironmentally-safe manner.

Do not leave unit unattended

while draining fuel tank.

Properly lift unit and secure

in a level position. Use ade-

quate blocks or stands to

support unit while draining

fuel tank.

Attach 1/2 ID hose to drain valve.

Put metal container under drain,

and use screwdriver to open

sludge drain valve. Close valve

when sludge has drained. Remove

hose.

Close door.

Tools Needed:

802 490 / Ref. 801 434

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OM-4406 Page 47

9-8. Overload Protection

Stop engine.

opens, it usually indicates a

more serious problem exists.

Contact Factory Authorized

Service Agent.

Fuse F1

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 out-

put is low or stops entirely. 4 kVA/kW

generator power is still available.

Circuit Breaker CB4 (Not

Shown)

Circuit Breaker CB5

(CC/CV Models Only)

Circuit Breaker CB6

(CC/CV Models Only)

Circuit Breaker CB10 (Not

Shown)

Circuit Breaker CB11

Circuit Breaker CB12

Circuit Breaker CB13

CB4 protects the welding arc drive

(dig) circuit. If CB4 opens, electrode

may stick to the workpiece more fre-

quently during low voltage (short arc

length) conditions. CB4 automatical-

ly resets when the fault is corrected.

CB5 protects the 24 volt ac output to

remote receptacle RC14, and 24 volt

output to field current regulator board

PC1 (CC/CV models only). If CB5

opens, weld output and 24 volt out-

put to RC14 stops. On units with op-

tional three−phase generator, gener-

ator power output at receptacle RC5

also stops if CB5 opens.

CB6 protects the 115 volt ac output

to remote receptacle RC14 (CC/CV

models 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 re-

sets 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 (generator power is still

available).

CB12 protects the field flashing cir-

cuit. If CB12 opens, the generator

may not excite at start-up and weld

and generator power output may not

be available.

CB13 protects the engine shutdown

circuit. If CB13 opens, the engine

cranks but does not start.

Press button to reset breaker.

802 170-D / Ref. 802 311

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OM-4406 Page 48

9-9. Diagnosing Causes Of Engine Fault Shutdowns

Use the front panel engine lights to

help determine the cause of an au-

tomatic engine shutdown.

. Correct the cause of the shut-

down before operating the

welding generator.

Pre-Start Diagnostic Checks

. This unit does not have a bat-

tery charging fault shutdown.

The engine continues to run if

the Battery Charging Light

goes on.

Normal Condition:

Oil Pressure Light On;

Battery Charging And Temperature Lights Off.

Turn Engine Control Switch To Run/Idle

Position While Pressing Magnetic

Shutdown Switch.

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.

Diagnostic Checks While Running

20s

Start Engine (With No Load Applied).

Continue Pressing Shutdown Switch

Until Engine Lights Go Off.

Normal Condition:

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

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9-10. Troubleshooting

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 9-8). Have Factory Authorized Service Agent check inte-

grated rectifier SR2 and the rotor.

Have Factory Authorized Service Agent check brushes and slip rings, and weld 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 9-8). 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 9-8).

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

Check and tighten connections inside and outside unit.

Erratic weld output.

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.

Check engine speed, and adjust if necessary.

High weld output.

Low weld output.

Have Factory Authorized Service Agent check OCV control circuit.

Check engine speed, and adjust if necessary.

Check fuses F1 and F2, and replace if open (see Section 9-8). 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 9-8).

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 speed, and adjust if necessary.

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).

Reset circuit breaker CB11 (see Section 9-8). Have Factory Authorized Service Agent check control relay

CR7.

Repair or replace remote control device.

Have Factory Authorized Service Agent check OCV control circuit.

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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 7 -1).

Check position of Ampere Range switch.

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

Reset circuit breaker CB11 (see Section 9-8).

Reset circuit breaker CB5 (see Section 9-8). 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 9-8). Have Factory Authorized Service Agent check

brushes and slip rings, weld 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 9-8). 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.

Check and tighten connections inside and outside unit.

Erratic weld output.

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.

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

High weld output.

Check engine speed, and adjust if necessary.

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 speed, and adjust if necessary.

Check fuses F1 and F2, and replace if open (see Section 9-8). 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 9-8).

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 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 9-8).

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.

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Trouble

Remedy

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.

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 9-8). 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 9-8).

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

High output at generator power ac re- Check engine speed, and adjust if necessary.

ceptacles.

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

Low output at generator power ac recep- Check engine speed, and adjust if necessary.

tacles.

Check fuse F1, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check inte-

grated rectifier SR1, resistor R3, and capacitor C9.

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

Trouble

Remedy

No or low output at optional three−

phase generator/receptacle RC5.

Place Process/Contactor switch in Electrode Hot - Stick position (see Section 7-3).

Reset circuit breaker CB7(see Section 8-2).

Reset circuit breaker CB5 (see Section 9-8).

Check engine weld/power speed, and adjust if necessary (see Section 9-6).

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

PC1.

High output at optional three−phase

generator/receptacle RC5.

Check engine weld/power speed, and adjust if necessary (see Section 9-6).

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/receptacleRC5.

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 9-8).

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.

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Trouble

Remedy

Press Magnetic Shutdown switch MS1 when starting engine.

Check fuel level.

Engine cranks but does not start.

Reset circuit breaker CB13 (see Section 9-8). Have Factory Authorized Service Agent check engine-

wiring harness and components.

Check battery and replace if necessary. Check engine charging system according to engine manual.

Have Factory Authorized Service Agent check 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, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant

temperatureis too high (see Sections 5-7 and 9-9).

Engine hard to start in cold weather.

Use starting aid switch (see Section 6-1 or 7-1).

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 oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant

temperatureis too high (see Sections 5-7 and 9-9).

See engine manual.

Check fuel level.

Engine slowly stopped and cannot be

restarted.

Check engine air and fuel filters (see Sections 9-4 and 9-7).

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).

Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1.

Engine idles, but does not come up to

weld speed.

Check for obstructed throttle solenoid.

Engine does not run at idle speed.

CC models: place Stick/TIG Selection switch in Stick position.

CC/CV models: place Process/Contactor switch in any position but Remote-TIG.

Check for obstructed throttle solenoid.

Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.

Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 11).

wetstacking occurs.

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SECTION 10 − ELECTRICAL DIAGRAMS

Figure 10-1. Circuit Diagram For CC Welding Generator

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215 296-B

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Figure 10-2. Circuit Diagram For CC/CV Welding Generator

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215 297-B

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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.

Welding Generator

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

generatoris kept loaded during

run-in.

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.

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OM-4406 Page 58

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

from flammables.

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.

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.

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.

Weld Cables

Connect load bank to generator

weld output terminals using proper

size weld cables with correct

connectors. Observe

polarity.

correct

Start engine and run for several

minutes.

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

generatoris loaded properly.

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.

Engine Exhaust Pipe

Repeat procedure if wetstacking is

present.

S-0683

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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

from flammables.

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.

Resistance Grid

Use grid sized for generator rated

output.

Turn Off grid.

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.

Weld Cables

Connect grid to generator weld

output terminals using proper size

weld cables with correct connec-

tors (polarity is not important).

Voltmeter

Clamp-On Ammeter

Connect voltmeter and ammeter as

shown, if not provided on generator.

Start engine and run for several

minutes.

Set grid switches and then adjust

generator A/V control so load

equals rated voltage and current of

the generator (see nameplate, rat-

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.

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.

Engine Exhaust Pipe

Repeat procedure if wetstacking is

present.

S-0684

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SECTION 12 − GENERATOR POWER GUIDELINES

The views in this section are intended to be representative of all engine-driven

welding generators. Your unit may differ from those shown.

NOTE

12-1. Selecting Equipment

Generator Power Receptacles

− Neutral Bonded To Frame

3-Prong Plug From Case

Grounded Equipment

2-Prong Plug From Double

Insulated Equipment

Do not use 2-prong plug un-

less equipment is double in-

sulated.

Be sure equipment

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.

Equipment Grounding

Terminal (On Front Panel)

Grounding Cable (Not

Supplied)

Metal Vehicle Frame

Connect cable from equipment

ground terminal to metal vehicle

frame. Use #10 AWG or larger

insulated copper wire.

GND/PE

If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

Electrically bond generator

frame to vehicle frame by

metal-to-metalcontact.

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

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12-3. Grounding When Supplying Building Systems

EquipmentGrounding

Terminal

Grounding Cable

GND/PE

Use #10 AWG or larger insulated

copper wire.

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.

ST-800 576-B

12-4. How Much Power Does Equipment Require?

Resistive Load

A light bulb is a resistive load and

requires a constant amount of power.

VOLTS 115

AMPS 4.5

Hz 60

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).

Rating Data

Rating shows volts and amperes, or

watts required to run equipment.

AMPERES x VOLTS = WATTS

EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power

requirementin 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

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OM-4406 Page 62

12-5. Approximate Power Requirements For Industrial Motors

Industrial Motors

Rating

Starting Watts

Running Watts

Split Phase

1/8 HP

1/6 HP

1/4 HP

1/3 HP

1/2 HP

1/3 HP

1/2 HP

3/4 HP

1 HP

800

1225

1600

2100

3175

2020

3075

4500

6100

8200

10550

15900

23300

8100

23300

35000

46700

1000

1400

1850

2400

3500

300

500

600

700

875

Capacitor Start-Induction Run

720

975

1400

1600

2200

2850

3900

6800

2000

6000

8000

10700

400

1-1/2 HP

2 HP

3 HP

5 HP

Capacitor Start-Capacitor Run

Fan Duty

1-1/2 HP

5 HP

7-1/2 HP

10 HP

1/8 HP

1/6 HP

1/4 HP

1/3 HP

1/2 HP

550

650

800

1100

12-6. Approximate Power Requirements For Farm/Home Equipment

Farm/HomeEquipment

Stock Tank De-Icer

Rating

Starting Watts

Running Watts

1000

1650

3400

4400

2900

10500

1720

2575

4500

6100

8200

10550

15900

23300

8100

23300

35000

46700

3300

3150

4500

6100

3100

2150

3100

2100

3200

1000

650

Grain Cleaner

1/4 HP

1/2 HP

3/4 HP

Portable Conveyor

Grain Elevator

1000

1400

1100

2800

720

Milk Cooler

Milker (Vacuum Pump)

FARM DUTY MOTORS

Std. (e.g. Conveyors,

Feed Augers, Air

Compressors)

2 HP

1/3 HP

1/2 HP

3/4 HP

1 HP

975

1400

1600

2200

2850

3900

6800

2000

6000

8000

10700

1000

950

1-1/2 HP

2 HP

3 HP

5 HP

High Torque (e.g. Barn

1-1/2 HP

5 HP

Cleaners, Silo Unloaders,

Silo Hoists, Bunk Feeders)

7-1/2 HP

10 HP

1/2 HP

500 PSI

550 PSI

700 PSI

3-1/2 cu. ft. Mixer

High Pressure 1.8 Gal/Min

Washer 2 gal/min

2 gal/min

1400

1600

800

Refrigerator or Freezer

Shallow Well Pump

1/3 HP

1/2 HP

1/3 HP

1/2 HP

750

1000

800

Sump Pump

1050

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12-7. Approximate Power Requirements For Contractor Equipment

Contractor

Rating

Starting Watts

Running Watts

Hand Drill

1/4 in

3/8 in

350

400

350

400

1/2 in

600

Circular Saw

Table Saw

6-1/2 in

7-1/4 in

8-1/4 in

9 in

500

900

1400

4500

6300

2500

1720

3900

5200

3000

6000

8200

10500

1100

350

1400

1500

1800

1100

720

10 in

Band Saw

14 in

Bench Grinder

6 in

8 in

1400

1600

1000

1500

2200

2800

1100

350

10 in

Air Compressor

1/2 HP

1 HP

1-1/2 HP

2 HP

Electric Chain Saw

Electric Trimmer

Electric Cultivator

1-1/2 HP, 12 in

2 HP, 14 in

Standard 9 in

Heavy Duty 12 in

1/3 HP

500

2100

400

700

Elec. Hedge Trimmer

Flood Lights

18 in

400

HID

125

100

Metal Halide

Mercury

Sodium

Vapor

313

250

1000

1400

1250

600

1000

200

Submersible Pump

Centrifugal Pump

Floor Polisher

400 gph

900 gph

3/4 HP, 16 in

1 HP, 20 in

1/2 HP

900

500

4500

6100

3150

4500

6100

1900

900

1400

1600

950

High Pressure Washer

3/4 HP

1400

1600

700

1 HP

55 gal Drum Mixer

Wet & Dry Vac

1/4 HP

1.7 HP

900

2-1/2 HP

1300

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12-8. Power Required To Start Motor

Motor Start Code

Running Amperage

Motor HP

AC MOTOR

VOLTS 230 AMPS 2.5

Hz 60

PHASE 1

CODE

1/4

Motor Voltage

To find starting amperage:

Step 1: Find code and use table to

find kVA/HP. If code is not listed,

multiplyrunning amperage by six to

find starting amperage.

Step 2: Find Motor HP and Volts.

Step 3: Determine starting amper-

age (see example).

Welding generator amperage out-

put must be at least twice the

motor’s running amperage.

Single-Phase Induction Motor Starting Requirements

Motor Start

Code

KVA/HP

6.3

7.1

8.0

9.0

10.0

11.2

12.5

14.0

kVA/HP x HP x 1000

VOLTS

= STARTING AMPERAGE

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?

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.

5 Second Rule

If motor does not start within 5

seconds, turn off power to prevent

motor damage. Motor requires

more power than generator can

supply.

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

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OM-4406 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.

Fused

Disconnect

Switch

Utility

Electrical

Service

Welding

Generator

Output

Transfer Switch

(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

Turn off or unplug all equipment connected to

generator before starting or stopping engine.

When starting or stopping, the engine has

low speed which causes low voltage and

frequency.

es.

restored.

Properly install and ground this Install correct switch (customer-supplied).

equipment according to its Owner’s Switch rating must be same as or greater

than the branch overcurrent protection.

Manual and national, state, and local

codes.

3 Fused Disconnect Switch

5 Essential Loads

. Customer-supplied equipment is re-

quired if generator will supply standby

power during emergencies or power out-

ages.

Install correct switch (customer-supplied) if

required by electrical code.

Generatoroutput may not meet the electrical

requirements of the premises. If generator

does not produce enough output to meet all

4 Welding Generator Output

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.

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OM-4406 Page 66

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

(Amperes)

Load (Watts)

600

350 (106)

250 (76)

175 (53)

112 (34)

87 (26)

62 (19)

50 (15)

37 (11)

225 (68)

150 (46)

112 (34)

75 (23)

50 (15)

37 (11)

137 (42)

100 (30)

62 (19)

37 (11)

30 (9)

100 (30)

62 (19)

50 (15)

30 (9)

840

400 (122)

275 (84)

175 (53)

137 (42)

112 (34)

87 (26)

1200

1800

2400

3000

3600

4200

4800

5400

6000

400 (122)

300 (91)

225 (68)

175 (53)

150 (46)

125 (38)

112 (34)

100 (30)

87 (26)

75 (23)

62 (19)

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

(Amperes)

Load (Watts)

1200

1680

2400

3600

4800

6000

7000

8400

9600

10,800

12,000

700 (213)

500 (152)

350 (107)

225 (69)

175 (53)

125 (38)

100 (31)

75 (23)

450 (137)

300 (91)

225 (69)

150 (46)

100 (31)

75 (23)

225 (84)

200 (61)

125 (38)

75 (23)

200 (61)

125 (38)

100 (31)

60 (18)

800 (244)

550 (168)

350 (107)

275 (84)

225 (69)

175 (53)

150 (46)

125 (38)

100 (31)

800 (244)

600 (183)

450 (137)

350 (107)

300 (91)

250 (76)

225 (69)

200 (61)

175 (53)

60 (18)

75 (23)

*Conductor size is based on maximum 2% voltage drop

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SECTION 13 − PARTS LIST

not available unless listed.

5 6

117

116

102

103

115 (FIG 13-7)

104

114

105

101

120

112

106 (FIG 13-2 OR 13-3)

100

108

113

107 (CC ONLY)

119

110

109

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

Figure 13-1. Main Assembly

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118

85 (Fig. 13-4)

802 550-E

OM-4406 Page 69

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 13-1. Main Assembly

Quantity

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

. . . 2 . . . . . . . . . . . . . 191 623 . . LABEL, warning all panels must be in place while running . . . . . . . . . . . . . 2

. . . 2 . . . . . . . . . . . . . 176 106 . . LABEL, warning moving parts (CE models only) . . . . . . . . . . . . . . . . . . . . . 2

. . . 3 . . . . . . . . . . . . +189 828 . . PANEL, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . . Z1 . . . ^C_C202 151 . . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . . Z1 . . . _V201 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 . . . . . . . . . . . . . 189 763 . . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . . . . . . . . . 189 764 . . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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

. . . 17 . . . . . . . . . . . . . 189 618 . . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 18 . . . . . . . . . . . . . 198 457 . . TUBE, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 19 . . . . . . . . . . . . . 173 036 . . HOSE, elbow air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 010 863 . . CLAMP, hose 1.125 − 3.000 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 20 . . . . . . . . . . . . . 189 464 . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 173 909 . . HOSE, sae .312 id x .560 od x 24.000 (order by ft) . . . . . . . . . . . . . . . . . . 2

. . . 21 . . . . . . . . . . . . . 201 658 . . UPRIGHT, center assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 22 . . . . . . . . . . . . . 191 819 . . HOSE, sae .312 id x .560 od x 14.000 (order by ft) . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . 198 584 . . HOSE, sae .312 id x .560 od x 5.000 (order by ft) . . . . . . . . . . . . . . . . . . . . 1

. . . 23 . . . . . . . . . . . . . 095 636 . . HOSE, sae .187 id x .41 od x 30.000 (order by ft) . . . . . . . . . . . . . . . . . . . 1

. . . 24 . . . . . . . . . . . . . 192 750 . . BASE, fuel filter w/adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 25 . . . . . . . . . . . . . *192 744 . . FILTER, fuel spin-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 26 . . . . . . . . . . . . . 192 741 . . BLOCK, spacer mtg filter base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 27 . . . . . . . . . . . . +201 934 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 28 . . . . . . . . . . . . . 189 052 . . GROMMET, plastic neck filler fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 29 . . . . . . . . . . . . . 190 198 . . . . CAP, tank screw-on 3.500 in w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 30 . . . . . . . . . . . . . 192 041 . . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 30 . . . . . . . . . . . . . 176 103 . . LABEL, use diesel fuel only (CE models only) . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 31 . . . . . . . . . . . . . 108 487 . . LABEL, warning falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 31 . . . . . . . . . . . . . 176 104 . . LABEL, warning falling equipment (CE models only) . . . . . . . . . . . . . . . . . 2

. . . 32 . . . . . . . . . . . . . 176 230 . . LABEL, warning hot exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 33 . . . . . . . . . . . . . 105 734 . . PIPE, muffler extension elbow 1.750 od . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 34 . . . . . . . . . . . . . 201 851 . . COVER, radiator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 35 . . . . . . . . . . . . . 191 354 . . SUPPORT, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 36 . . . . . . . . . . . . . 010 875 . . CLAMP, muffler 2.000 dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 37 . . . . . . . . . . . . . 203 180 . . MANIFOLD, exhaust muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 203 179 . . BRACKET, support muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 38 . . . . . . . . . . . . . 213 185 . . ENGINE, Caterpillar 3024C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *215 093 . . . . SWITCH, coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *215 094 . . . . SWITCH, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 192 664 . . HOSE, pvc .500 id x .750 od x 10.000 (order by ft) . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 198 694 . . FTG, hose poly barbed 5/8id x 1/2id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

. . . . . . . . . . . . . . . . . . . *202 166 . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

. . . . . . . . . . . . . . . . . . . *202 167 . . FILTER, fuel secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 39 . . . . . . . . . . . . . 202 017 . . GUARD, belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Figure 13-1. Main Assembly (Continued)

. . . 40 . . . . . . . . . . . . . 214 658 . . HOSE, radiator upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 41 . . . . . . . . . . . . . *197 944 . . BELT, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 42 . . . . . . . . . . . . +215 006 . . GUARD, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 43 . . . . . . . . . . . . . 214 884 . . RADIATOR, w/14# cap 4 row core 3 pass . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 187 120 . . . . CAP, radiator pressure 14lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 214 885 . . SHROUD, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 44 . . . . . . . . . . . . . 201 749 . . UPRIGHT, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 45 . . . . . . . . . . . . . 190 206 . . CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng . . . . . . . . . . . . . 1

. . . 46 . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 47 . . . . . . . . . . . . . 190 207 . . CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng . . . . . . . . . . . . . 1

. . . 48 . . . . . . . . . . . . . 203 430 . . BRACKET, battery holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 49 . . . . . . . . . . . . . 190 897 . . BATTERY, stor 12V 650crk 110rsv gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 50 . . . . . . . . . . . . . 201 006 . . BOLT, j stl .312−18 x 8.500 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 51 . . . . . . . . . . . . +201 183 . . COVER, battery access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 52 . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 52 . . . . . . . . . . . . . 176 108 . . LABEL, warning battery explosion can blind (CE models only) . . . . . . . . . 1

. . . 53 . . . . . . . . . . . . . 201 996 . . LABEL, warning do not operate with guard missing . . . . . . . . . . . . . . . . . . 2

. . . 54 . . . . . . . . . . . . . 197 496 . . HOSE, radiator lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 199 505 . . HOSE, oil drain assy 32 in (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 55 . . . . . . . . . . . . . 165 271 . . . . VALVE, oil drain 3/8-18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 56 . . . . . . . . . . . . . 176 529 . . . . FITTING, hose brs barbed fem 1/2tbg x 3/8NPT . . . . . . . . . . . . . . . . . . . 1

. . . 57 . . . . . . . . . . . . . . 113 854 . . . . HOSE, SAE .500 ID x .780 OD xc oil (order by ft) . . . . . . . . . . . . . . . . . . 3ft

. . . 58 . . . . . . . . . . . . . 197 448 . . FITTING, hose brs barbed elbow m 1/2 tbg x 3/8 npt . . . . . . . . . . . . . . . . . 1

. . . 59 . . . . . . . . . . . . . . . . . . . . . . . . WASHER, oil drain (available through engine manufacturer) . . . . . . . . . . . 1

. . . 60 . . . . . . . . . . . . . 197 196 . . FITTING, adapter oil drain 12mm male x 3/8 npt female . . . . . . . . . . . . . . 1

. . . 61 . . . . . . . . . . . . . 190 992 . . KEEPER, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 62 . . . . . . . . . . . . . 190 076 . . CHANNEL, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 63 . . . . . . . . . . . . . 199 592 . . LATCH, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 64 . . . . . . . . . . . . . 202 165 . . LABEL, diesel engine maintenance Caterpillar 3024 . . . . . . . . . . . . . . . . . . 1

. . . 65 . . . . . . . . . . . . +200 989 . . DOOR, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 66 . . . . . . . . . . . . . 189 975 . . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 67 . . . . . . . . . . . . . 190 190 . . TANK, coolant recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 68 . . . . . . . . . . . . . 208 141 . . STOP, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 69 . . . . . . . . . . . . . 189 826 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 70 . . . . . . . . . . . . . 191 626 . . BUMPER, door engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 71 . . . . . . . . . . . . . 189 827 . . PANEL, gen RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 72 . . . . . . . . . . . . . 199 849 . . SCREW, 625-11 x 4.00hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 73 . . . . . . . . . . . . . 071 731 . . WASHER, flat .656 ID x 2.250 OD x .187T stl pld . . . . . . . . . . . . . . . . . . . . 4

. . . 74 . . . . . . . . . . . . . 197 489 . . BRACKET, mtg RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 197 488 . . BRACKET, mtg LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 75 . . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 76 . . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 77 . . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 . . . . . . . . . . . . . . . . . . 4

. . . 78 . . . . . . . . . . . . . 135 205 . . NUT, 625-11 .94hex .76H stl pld elastic stop nut . . . . . . . . . . . . . . . . . . . . . 4

. . . 79 . . . . . . . . . . . . . *197 997 . . FILTER, fuel secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 80 . . . . . . . . . . . . . . . . . . . . . . . . PUMP, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 81 . . . . . . . . . . . . . 173 909 . . HOSE, sae .312 id x .560 od (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 82 . . . . . . . . . . . . . 198 548 . . BRACKET, mtg fuel filter/pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 83 . . . . . . . . . . . . ♦198 624 . . IDLE SOLENOID ASSEMBLY (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 049839 . . . . Bracket, Adjustment Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 080517 . . . . Solenoid, 12vdc Pull Type Tubular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 203716 . . . . Bracket, Mtg Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 605277 . . . . Pin, Cotter .093 X .750 Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 198370 . . . . Rod, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 206209 . . . . Ball Joint, .250−28 Thd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 198609 . . . . Arm, Throttle 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 84 . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 84 . . . . . . . . . . . . . 176 106 . . LABEL, warning moving parts (CE models only) . . . . . . . . . . . . . . . . . . . . . 2

OM-4406 Page 71

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Figure 13-1. Main Assembly (Continued)

. . . 85 . . . . . . . . . . . Figure13-6 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 86 . . . . . . . . . . . . . 095 636 . . HOSE, sae .312 id x .560 od x 14.000 (order by ft) . . . . . . . . . . . . . . . . . . . 1

. . . 87 . . . . . . . . . . . . . 189 245 . . TANK, fuel 23gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 88 . . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . . . . . . . . . . . . . . . . . 084 173 . . . . CLAMP, hose .460 − .545clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 89 . . . . . . . . . . . . . 189 912 . . . . FITTING, stl barbed elbow w/.047 in orf zinc pld . . . . . . . . . . . . . . . . . . . 1

. . . 90 . . . . . . . . . . . . . 189 909 . . . . FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc . . . . . . . . . . . . . . . 1

. . . 91 . . . . . . . . . . . . . 201 025 . . . . CAP, fuel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 92 . . . . . . . . . . . . . 189 913 . . . . FITTING, stl barbed elbow zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 93 . . . . . . . . . . . . . 190 142 . . . . SENDER, fuel gauge 9.7500 deep tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 94 . . . . . . . . . . . . . 189 910 . . . . FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc . . . . . . . . . . . . . 1

. . . 95 . . . . . . . . . . . . . 189 908 . . . . VALVE, drain fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 96 . . . . . . . . . . . . . 181 572 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 97 . . . . . . . . . . . . . 191 446 . . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . . . 6ft

. . . 98 . . . . . . . . . . . . . 190 179 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 99 . . . . . . . . . . . . . 190 250 . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 99 . . . . . . . . . . . . . 200 864 . . LABEL, do not weld on base ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . 100 . . . . . . . . . . . . 191 897 . . BRACKET, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . 101 . . . . . . . . . . . . 192 362 . . BRACKET, mtg nyl 1/2 conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 102 . . . . . . . . . . . . 196 220 . . BRACKET, hold down fuel tank rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 103 . . . . . . . . . . . +200 999 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 104 . . . . . . . . . . . . 191 512 . . BRACKET, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 105 . . . . . . . . . . . . 189 731 . . FIREWALL, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 106 . . . . . Figure 13-2, 13-3 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 107 . . . . R2 . . . ^C_C189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1

. . 108 . . . . R3 . . . . 189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1

. . 109 . . . . . . . . . . . +201 750 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 110 . . . . . . . . . . . . 182 761 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 110 . . . . . . . . . . . . 176 105 . . LABEL, warning general precautionary (CE models only) . . . . . . . . . . . . . 1

. . 111 . . . . . . . . . . . . . 13-4, 13-5 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 112 . . . . . . . . . . . . . 202130 . . XFMR, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 113 . . . . . . . . . . . . 176 109 . . LABEL, caution using ether to aid engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 114 . . . . . . . . . . . . 191 448 . . TOP, cover front upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 115 . . . . . . . . . Figure 13-7 . . MAIN RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 116 . . . . . . . . . . . _V193 453 . . BRACKET, mtg box fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 117 . . . PC1 . . _V189 143 . . MODULE, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 118 . . . . . . . . . . . +147 923 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . 1

. . 119 . . . . . . . . . . . ♦138 074 . . LABEL, warning electric shock do not use AC output . . . . . . . . . . . . . . . . . 1

. . 120 . . . . . . . . . . . . 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

. . . . . . . . . . . . . . . . . . . 202 758 . . KIT, label (includes safety and informational labels) . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 201 061 . . KIT, label (includes safety and informational labels) (CE models only) . . 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 202 758.

*Recommended Spare Parts.

CC models only.

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.

Return T o T a ble Of Contents

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Ref. 802 551-E

Figure 13-2. Control Box Assembly − CC Models

Item

No.

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Mkgs.

Part

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Quantity

Figure 13-2. Control Box Assembly − CC Models (Figure 13-1 Item 106)

. . . 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 . . . D1/C1 . . 189 701 . . . . DIODE/CAPACITOR 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 13-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . S6 . . . . . 011 622 . . . . SWITCH, tgl 3pdt 15a 125vac on−none−on spd term

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see 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

OM-4406 Page 73

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

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

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

. . . . . . . . . . PLG3 . . . . 158465 . . . . CONN, rect univ 084 12p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 187654 . . . . SEAL, wire univ 12p/s 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG6 . . . . 114063 . . . . CONN, rect univ 084 4p/s 1row plug cable lkg . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 192309 . . . . 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

. . . . . . . . . . . . . . . . . . . 212 452 . . HARNESS, engine control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 19 D10/C10, D11/C11 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 20 . . . . . R8 . . . . 217 335 . . . . RESISTOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . 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

. . . 22 . . . . CR1 . . . 214 876 . . . . RELAY, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 23 . . . . CR9 . . . 090 104 . . . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . 1

. . . 24 . . . . CR8 . . . 155 309 . . CONTACTOR, Solenoid 12vdc Continuous 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.

802 360

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

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1 Item 106)

. . . 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 13-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH,tgl spdt 15a 125vac on−none−on spd term chr

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see 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

. . . . . . . . . . . . . . . . . . . 212 452 . . HARNESS, engine control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 17 D10/C10, D11/C11 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 18 . . . . . R8 . . . . 217 335 . . . . RESISTOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 19 . . . . 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

. . . 20 . . . . CR1 . . . 214 876 . . . . RELAY, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . CR9 . . . 090 104 . . . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . 1

. . . 22 . . . . CR8 . . . 155 309 . . CONTACTOR, Solenoid 12vdc Continuous 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.

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802 266-E

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

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 13-4. Panel, Front w/Components − CC Models (Figure 13-1 Item 111)

Quantity

. . . 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

. . . 4 . . . . . S3 . . . . 189 382 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

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

. . . 7 . . . . . S6 . . . . . 011 622 . . SWITCH, tgl DPDT 15A 125VAC (included in control box harness,

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see 13-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 8 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see 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, generator 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 . . . . . . . . . . . ♦+210 750 . . PANEL, gen pwr ss (CE models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

. . . 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 . . . . . . . . . . . . . 201 045 . . COVER, receptacle twistlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 37 . . . . . PL1 . . . 191 241 . . LED, red 12V 4 ind lights panel mtg round . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 38 . . . . FUEL . . . 192 265 . . GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 39 . . . . . HM . . . . . 118 058 . . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 40 . . . . . . . . . . . ♦193 228 . . METER, Volt Dc 8− 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . 1

. . . 41 . . . . . . . . . . . ♦193 229 . . GAUGE, Coolant Temp 0− 300 Deg F Electric Switch . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . ♦197 798 . . SENDER, Coolant Temp 300 Deg F M16 X 1.5 (Caterpillar 3024) . . . . . . 1

. . . 42 . . . . . . . . . . . ♦193 227 . . GAUGE, Pressure Oil 0−100 Psi Electric Switch . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . ♦193 230 . . SENDER, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 43 . . . . . . . . . . . ♦194 348 . . AMMETER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . ♦030 084 . . SHUNT, Meter 50mv 600 Amp Lt Wt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 44 . . . . . . . . . . . ♦194 345 . . VOLT METER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 45 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 46 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 47 . . . . . . . . . . . . . 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 202 758.

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-4406 Page 77

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not available unless listed.

802 332-F

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

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 13-5. Panel, Front w/Components − CC/CV Models (Figure 13-1 Item 111)

. . . 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

. . . 4 . . . . . S3 . . . . 189 382 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

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

. . . 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 13-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see 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, gen power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 24 . . . . . . . . . . . +♦201 107 . . PANEL, gen 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

. . . 35 . . . . . S12 . . ♦211 137 . . SWITCH, polarity/AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦070572 . . Label, Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦070571 . . Label, Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦203305 . . Label, 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

OM-4406 Page 79

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Item

No.

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Part

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

. . . 50 . . . . . . . . . . . . . 170 391 . . CONN, circ ms protective cap size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 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 . . . . . . . . . . . ♦193 228 . . METER, Volt Dc 8− 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . 1

. . . 55 . . . . . . . . . . . ♦193 229 . . GAUGE, Coolant Temp 0− 300 Deg F Electric Switch . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . ♦197 798 . . SENDER, Coolant Temp 300 Deg F M16 X 1.5 (Caterpillar 3024) . . . . . . 1

. . . 56 . . . . . . . . . . . ♦193 227 . . GAUGE, Pressure Oil 0−100 Psi Electric Switch . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . ♦193 230 . . SENDER, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 57 . . . . . . . . . . . ♦194 348 . . AMMETER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . ♦030 084 . . SHUNT, Meter 50mv 600 Amp Lt Wt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 58 . . . . . . . . . . . ♦194 345 . . VOLT METER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 59 . . . . . . . . . . . . . 097 922 . . KNOB, pointer .875 dia x .250 ID w/set screws plstc . . . . . . . . . . . . . . . . . 1

. . . 60 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 61 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 62 . . . . . . . . . . . . . 097 924 . . KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc . . . . . . . . . . . . . . . . . 1

. . . 63 . . . . 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 202 758.

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.

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not available unless listed.

802 552-A

Figure 13-6. Generator

Item

No.

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Part

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Description

Quantity

Figure 13-6 . Generator (Figure 13-1 Item 85)

. . . 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 . . . . . . . . . . . . . 197 487 . . . . FLYWHEEL, Perkins 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Part

No.

Description

Quantity

Figure 13-6. Generator (Continued)

. . . 21 . . . . . . . . . . . . . 197 486 . . ADAPTER, Engine Perkins 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 202 758.

*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.

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 13-7 . Main Rectifier Assembly (Figure 13-1 Item 115)

. . . . . . . . . . . . . . . . . . . 201 747 . . RECTIFIER (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 037 956 . . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 9 . D2, D4, D6 037 957 . . . . 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.

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not available unless listed.

802 279-A

Figure 13-7. Main Rectifier Assembly

OM-4406 Page 83

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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

guarantees or warranties expressed or implied.

Warranty Questions?

LIMITED WARRANTY − Subject to the terms and conditions

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants

to its original retail purchaser that new Miller equipment sold

after the effective date of this limited warranty is free of defects

in material and workmanship at the time it is shipped by Miller.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.

Induction Heating Coils and Blankets

APT & SAF Model Plasma Cutting Torches

Remote Controls

Accessory Kits

Replacement Parts (No labor)

Spoolmate Spoolguns

Call

1-800-4-A-MILLER

for your local

Miller distributor.

Canvas Covers

Within the warranty periods listed below, Miller will repair or

replace any warranted parts or components that fail due to

such defects in material or workmanship. Miller must be

notified in writing within thirty (30) days of such defect or

failure, at which time Miller will provide instructions on the

warranty claim procedures to be followed.

Your distributor also gives

you ...

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

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings,

relays or parts that fail due to normal wear.

(Exception: brushes, slip rings, and relays are

covered on Bobcat, Trailblazer, and Legend models.)

Service

You always get the fast,

reliable response you

need. Most replacement

parts can be in your

hands in 24 hours.

Miller shall honor warranty claims on warranted equipment

listed below in the event of such a failure within the warranty

time periods. All warranty time periods start on the date that

the equipment was delivered to the original retail purchaser, or

one year after the equipment is sent to a North American

distributor or eighteen months after the equipment is sent to an

International distributor.

2. Items furnished by Miller, but manufactured by others,

such as engines or trade accessories. These items are

covered by the manufacturer’s warranty, if any.

Support

Need fast answers to the

tough welding questions?

Contact your distributor.

The expertise of the

distributor and Miller is

there to help you, every

step of the way.

3. Equipment that has been modified by any party other

than Miller, or equipment that has been improperly

installed, improperly operated or misused based upon

industry standards, or equipment which has not had

reasonable and necessary maintenance, or equipment

which has been used for operation outside of the

specifications for the equipment.

1. 5 Years Parts — 3 Years Labor

Original main power rectifiers

Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

MILLER PRODUCTS ARE INTENDED FOR PURCHASE

AND USE BY COMMERCIAL/INDUSTRIAL USERS AND

PERSONS TRAINED AND EXPERIENCED IN THE USE

AND MAINTENANCE OF WELDING EQUIPMENT.

Transformer/Rectifier Power Sources

Plasma Arc Cutting Power Sources

Semi-Automatic and Automatic Wire Feeders

Inverter Power Supplies

Intellitig

In the event of a warranty claim covered by this warranty, the

exclusive remedies shall be, at Miller’s option: (1) repair; or (2)

replacement; or, where authorized in writing by Miller in

appropriate cases, (3) the reasonable cost of repair or

replacement at an authorized Miller service station; or (4)

payment of or credit for the purchase price (less reasonable

depreciation based upon actual use) upon return of the goods

at customer’s risk and expense. Miller’s option of repair or

replacement will be F.O.B., Factory at Appleton, Wisconsin, or

F.O.B. at a Miller authorized service facility as determined by

Miller. Therefore no compensation or reimbursement for

transportation costs of any kind will be allowed.

Maxstar 150

Engine Driven Welding Generators

(NOTE: Engines are warranted separately by

the engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

DS-2 Wire Feeder

Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR

ANY OTHER LEGAL THEORY.

Process Controllers

Positioners and Controllers

Automatic Motion Devices

RFCS Foot Controls

Induction Heating Power Sources

Water Coolant Systems

Flowgauge and Flowmeter Regulators (No Labor)

HF Units

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN

AND ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

Grids

Maxstar 85, 140

Spot Welders

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION OF LAW, CUSTOM OF TRADE OR COURSE

OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL

EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND

DISCLAIMED BY MILLER.

Load Banks

Racks

Running Gear/Trailers

Some states in the U.S.A. do not allow limitations of how long

an implied warranty lasts, or the exclusion of incidental,

indirect, special or consequential damages, so the above

limitation or exclusion may not apply to you. This warranty

provides specific legal rights, and other rights may be

available, but may vary from state to state.

Plasma Cutting Torches (except APT & SAF

Models)

Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,

and to the extent that they may not be waived, the limitations

and exclusions set out above may not apply. This Limited

Warranty provides specific legal rights, and other rights may

be available, but may vary from province to province.

4. 6 Months — Batteries

5. 90 Days — Parts

MIG Guns/TIG Torches

miller_warr 8/03

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Owner’s Record

Please complete and retain with your personal records.

Model Name

Purchase Date

Distributor

Address

Serial/Style Number

(Date which equipment was delivered to original customer.)

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.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

Replacement Parts

Training (Schools, Videos, Books)

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

Welding Process Handbooks

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

 2004 Miller Electric Mfg. Co. 1/04

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