Miller Electric Welding System Big 40 WG User Manual
OM-4405  
200 972A  
January 2001  
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  
R
Big 40 WG  
Visit our website at  
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. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .  
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1
1
1
2
3
4
4
WARNING  
This product, when used  
for welding or cutting,  
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.)  
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .  
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
5
5
5
6
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement  
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
7
8
8
1-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
WARNING  
1-6. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Battery posts, terminals  
and related accessories  
contain lead and lead  
compounds, chemicals  
known to the State of  
California to cause  
cancer and birth defects  
or other reproductive  
harm. Wash hands after  
handling.  
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
9
2-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
9
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-3. Volt-Ampere Curves For CC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-4. Volt-Ampere Curves for CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-5. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-7. AC Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-8. Optional AC Power Plant Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
9
9
10  
10  
11  
12  
12  
13  
13  
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
4-1. Installing Welding Generator (See Sections 4-2 And 4-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-2. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-5. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-6. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-7. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-9. Selecting Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models . . . . . . . . . . . . .  
4-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models . . . . . . . . . . . . . . . . . . . . . .  
14  
14  
15  
15  
16  
17  
18  
19  
19  
20  
21  
WARNING  
The engine exhaust from  
this product contains  
chemicals known to the  
State of California to  
cause cancer, birth  
defects, or other  
reproductive harm.  
The following terms are  
used interchangeably  
throughout this manual:  
SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . 22  
5-1. Front Panel Controls For CC Models (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
5-2. Description Of Front Panel Controls For CC Models (See Section 5-1) . . . . . . . . . . . . . . . . .  
5-3. Remote Amperage Control On CC Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
22  
23  
24  
Stick = SMAW  
TIG = GTAW  
MIG = GMAW  
SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS . . . . . . . . . . . . . . . . . . . . . . 26  
6-1. Front Panel Controls For CC/CV Models (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . .  
6-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1) . . . . . . . . . . . . . .  
6-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
6-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) . . . . . . . . . . . . . . . . . . . . .  
26  
27  
28  
29  
SECTION 7 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30  
7-1. 120 Volt And 240 Volt Duplex Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
7-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only) . . . . . . . . . . . . . . . . . .  
7-3. Optional Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
30  
31  
32  
(Continued)  
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TABLE OF CONTENTS  
SECTION 8 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33  
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
8-3. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
8-5. Adjusting Engine Weld/Power Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
8-6. Adjusting Engine Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
8-7. Adjusting Governor Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
8-9. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
8-10. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
8-11. Diagnosing Causes Of Engine Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
8-12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48  
SECTION 10 – AUXILIARY POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52  
SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60  
OPTIONS AND ACCESSORIES  
WARRANTY  
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING  
rom _nd_11/98  
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  
Y
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.  
.
M
e
a
n
s
“
N
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e
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;
n
o
t
s
a
f
e
t
y
r
e
l
a
t
e
d
.
1-2. Arc Welding Hazards  
Y
The symbols shown below are used throughout this manual to  
call attention to and identify possible hazards. When you see  
the symbol, watch out, and follow the related instructions to  
avoid the hazard. The safety information given below is only  
a summary of the more complete safety information found in  
the Safety Standards listed in Section 1-5. Read and follow all  
Safety Standards.  
D
D
D
Wear a safety harness if working above floor level.  
Keep all panels and covers securely in place.  
Clamp work cable with good metal-to-metal contact to workpiece  
or worktable as near the weld as practical.  
D
D
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.  
Y
Y
Only qualified persons should install, operate, maintain, and  
repair this unit.  
During operation, keep everybody, especially children, away.  
SIGNIFICANT DC VOLTAGE exists after stopping  
engine on inverters.  
ELECTRIC SHOCK can kill.  
D
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  
ARC RAYS can burn eyes and skin.  
Arc rays from the welding process produce intense  
visible and invisible (ultraviolet and infrared) rays  
that can burn eyes and skin. Sparks fly off from the  
weld.  
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  
groundedequipment is a hazard.  
D
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).  
D
D
D
Do not touch live electrical parts.  
Wear dry, hole-free insulating gloves and body protection.  
Insulate yourself from work and ground using dry insulating mats  
or covers big enough to prevent any physical contact with the work  
or ground.  
D
D
D
Wear approved safety glasses with side shields under your  
helmet.  
Use protective screens or barriers to protect others from flash and  
glare; warn others not to watch the arc.  
D
Do not use AC output in damp areas, if movement is confined, or if  
there is a danger of falling.  
Wear protective clothing made from durable, flame-resistant mate-  
rial (wool and leather) and foot protection.  
D
D
Use AC output ONLY if required for the welding process.  
If AC output is required, use remote output control if present on  
unit.  
FUMES AND GASES can be hazardous.  
D
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).  
Welding produces fumes and gases. Breathing  
these fumes and gases can be hazardous to your  
health.  
D
D
Properly install and ground this equipment according to its  
Owner’s Manual and national, state, and local codes.  
D
D
Keep your head out of the fumes. Do not breathe the fumes.  
If inside, ventilate the area and/or use exhaust at the arc to remove  
welding fumes and gases.  
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  
groundedreceptacle outlet.  
D
D
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.  
D
D
When making input connections, attach proper grounding conduc-  
tor first – double-check connections.  
D
Work in a confined space only if it is well ventilated, or while  
wearing an air-supplied respirator. Always have a trained watch-  
person nearby. Welding fumes and gases can displace air and  
lower the oxygen level causing injury or death. Be sure the breath-  
ing air is safe.  
Frequently inspect input power cord for damage or bare wiring –  
replace cord immediately if damaged – bare wiring can kill.  
D
D
D
D
Turn off all equipment when not in use.  
Do not use worn, damaged, undersized, or poorly spliced cables.  
Do not drape cables over your body.  
D
D
Do not weld in locations near degreasing, cleaning, or spraying op-  
erations. The heat and rays of the arc can react with vapors to form  
highly toxic and irritating gases.  
If earth grounding of the workpiece is required, ground it directly  
with a separate cable.  
Do not weld on coated metals, such as galvanized, lead, or  
cadmiumplated steel, unless the coating is removed from the weld  
area, the area is well ventilated, and if necessary, while wearing an  
air-suppliedrespirator. The coatings and any metals containing  
these elements can give off toxic fumes if welded.  
D
D
Do not touch electrode if you are in contact with the work, ground,  
or another electrode from a different machine.  
Use only well-maintained equipment. Repair or replace damaged  
parts at once. Maintain unit according to manual.  
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WELDING can cause fire or explosion.  
HOT PARTS can cause severe burns.  
D
D
Allow cooling period before maintaining.  
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.  
Wear protective gloves and clothing when  
working on a hot engine.  
D
Do not touch hot engine parts or just-welded  
parts bare-handed.  
NOISE can damage hearing.  
D
D
D
Protect yourself and others from flying sparks and hot metal.  
Do not weld where flying sparks can strike flammable material.  
Noise from some processes or equipment can  
damagehearing.  
Remove all flammables within 35 ft (10.7 m) of the welding arc. If  
this is not possible, tightly cover them with approved covers.  
D
Wear approved ear protection if noise level is  
high.  
D
Be alert that welding sparks and hot materials from welding can  
easily go through small cracks and openings to adjacent areas.  
D
D
Watch for fire, and keep a fire extinguisher nearby.  
MAGNETIC FIELDS can affect pacemakers.  
Be aware that welding on a ceiling, floor, bulkhead, or partition can  
cause fire on the hidden side.  
D
D
Pacemaker wearers keep away.  
D
D
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).  
Wearers should consult their doctor before  
going near arc welding, gouging, or spot  
welding operations.  
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.  
D
D
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.  
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.  
D
D
Wear oil-free protective garments such as leather gloves, heavy  
shirt, cuffless trousers, high shoes, and a cap.  
Remove any combustibles, such as a butane lighter or matches,  
from your person before doing any welding.  
D
D
Protect compressed gas cylinders from excessive heat, mechani-  
cal shocks, slag, open flames, sparks, and arcs.  
Install cylinders in an upright position by securing to a stationary  
support or cylinder rack to prevent falling or tipping.  
FLYING METAL can injure eyes.  
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.  
Never drape a welding torch over a gas cylinder.  
D
Welding, chipping, wire brushing, and grinding  
cause sparks and flying metal. As welds cool,  
they can throw off slag.  
Never allow a welding electrode to touch any cylinder.  
Never weld on a pressurized cylinder – explosion will result.  
D
Wear approved safety glasses with side  
shields even under your welding helmet.  
Use only correct shielding gas cylinders, regulators, hoses, and fit-  
tings designed for the specific application; maintain them and  
associated parts in good condition.  
D
D
Turn face away from valve outlet when opening cylinder valve.  
BUILDUP OF GAS can injure or kill.  
Keep protective cap in place over valve except when cylinder is in  
use or connected for use.  
D
D
Shut off shielding gas supply when not in use.  
Always ventilate confined spaces or use ap-  
proved air-supplied respirator.  
D
Read and follow instructions on compressed gas cylinders,  
associated equipment, and CGA publication P-1 listed in Safety  
Standards.  
1-3. Engine Hazards  
STEAM AND HOT COOLANT can burn.  
FUEL can cause fire or explosion.  
D
D
If possible, check coolant level when engine is  
cold to avoid scalding.  
D
D
Stop engine and let it cool off before checking or  
adding fuel.  
Always check coolant level at overflow tank, if  
present on unit, instead of radiator (unless told  
otherwise in maintenance section or engine  
manual).  
Do not add fuel while smoking or if unit is near  
any sparks or open flames.  
D
If the engine is warm, checking is needed, and  
there is no overflow tank, follow the next two  
statements.  
D
D
D
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.  
D
D
Wear safety glasses and gloves and put a rag over radiator cap.  
Turn cap slightly and let pressure escape slowly before completely  
removing cap.  
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BATTERY ACID can BURN SKIN and  
EYES.  
MOVING PARTS can cause injury.  
D
D
Keep away from fans, belts, and rotors.  
D
D
D
Do not tip battery.  
Keep all doors, panels, covers, and guards  
closed and securely in place.  
Replace damaged battery.  
Flush eyes and skin immediately with water.  
D
D
Stop engine before installing or connecting unit.  
Have only qualified people remove guards or covers for maint-  
enance and troubleshooting as necessary.  
D
D
D
D
D
To prevent accidental starting during servicing, disconnect  
negative (–) battery cable from battery.  
ENGINE EXHAUST GASES can kill.  
Keep hands, hair, loose clothing, and tools away from moving  
parts.  
D
D
Use equipment outside in open, well-ventilated  
areas.  
Reinstall panels or guards and close doors when servicing is  
finished and before starting engine.  
If used in a closed area, vent engine exhaust  
outside and away from any building air intakes.  
Before working on generator, remove spark plugs or injectors to  
keep engine from kicking back or starting.  
Block flywheel so that it will not turn while working on generator  
components.  
ENGINE HEAT can cause fire.  
D
D
Do not locate unit on, over, or near combustible  
surfaces or flammables.  
BATTERY EXPLOSION can BLIND.  
Keep exhaust and exhaust pipes way from  
flammables.  
D
D
Always wear a face shield, rubber gloves, and  
protective clothing when working on a battery.  
Stop engine before disconnecting or connect-  
ing battery cables or servicing battery.  
EXHAUST SPARKS can cause fire.  
D
D
D
D
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.  
D
D
Do not let engine exhaust sparks cause fire.  
Use approved engine exhaust spark arrestor in  
required areas – see applicable codes.  
Disconnect negative (–) cable first and connect it last.  
1-4. Additional Symbols For Installation, Operation, And Maintenance  
OVERUSE can cause OVERHEATING.  
FALLING UNIT can cause injury.  
D
D
Allow cooling period; follow rated duty cycle.  
D
Use lifting eye to lift unit only, NOT running  
gear, gas cylinders, trailer, or any other  
accessories.  
Reduce current or reduce duty cycle before  
starting to weld again.  
D
Use equipment of adequate capacity to lift and  
support unit.  
D
Do not block or filter airflow to unit.  
D
If using lift forks to move unit, be sure forks are long enough to  
extend beyond opposite side of unit.  
STATIC (ESD) can damage PC boards.  
D
D
Put on grounded wrist strap BEFORE handling  
boards or parts.  
FLYING SPARKS can cause injury.  
Use proper static-proof bags and boxes to  
store, move, or ship PC boards.  
D
D
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.  
TILTING OF TRAILER can cause injury.  
D
Sparks can cause fires — keep flammables away.  
D
D
Use tongue jack or blocks to support weight.  
Properly install welding generator onto trailer  
according to instructions supplied with trailer.  
OVERHEATING can damage motors.  
D
Turn off or unplug equipment before starting or  
stopping engine.  
READ INSTRUCTIONS.  
D
Do not let low voltage and frequency caused by  
low engine speed damage electric motors.  
D
D
Use only genuine MILLER replacement parts.  
Perform engine maintenance and service  
according to this manual and the engine  
manual.  
D
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle  
where applicable.  
OM-4405 Page 3  
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H.F. RADIATION can cause interference.  
ARC WELDING can cause interference.  
D
High-frequency (H.F.) can interfere with radio  
navigation, safety services, computers, and  
communicationsequipment.  
D
Electromagnetic energy can interfere with  
sensitive electronic equipment such as  
computers and computer-driven equipment  
such as robots.  
D
Have only qualified persons familiar with  
electronic equipment perform this installation.  
D
Be sure all equipment in the welding area is  
electromagneticallycompatible.  
D
D
The user is responsible for having a qualified electrician prompt-  
ly correct any interference problem resulting from the installa-  
tion.  
D
D
D
D
To reduce possible interference, keep weld cables as short as  
possible, close together, and down low, such as on the floor.  
If notified by the FCC about interference, stop using the  
equipmentat once.  
Locate welding operation 100 meters from any sensitive elec-  
tronic equipment.  
D
D
Have the installation regularly checked and maintained.  
Be sure this welding machine is installed and grounded  
according to this manual.  
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.  
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.  
1-5. Principal Safety Standards  
Safety in Welding and Cutting, ANSI Standard Z49.1, from American  
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126  
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,  
from Compressed Gas Association, 1235 Jefferson Davis Highway,  
Suite 501, Arlington, VA 22202.  
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-  
dent of Documents, U.S. Government Printing Office, Washington, D.C.  
20402.  
Code for Safety in Welding and Cutting, CSA Standard W117.2, from  
Canadian Standards Association, Standards Sales, 178 Rexdale  
Boulevard, Rexdale, Ontario, Canada M9W 1R3.  
Recommended Safe Practices for the Preparation for Weldingand Cut-  
ting of Containers That Have Held Hazardous Substances, American  
Welding Society Standard AWS F4.1, from American Welding Society,  
550 N.W. LeJeune Rd, Miami, FL 33126  
Safe Practices For Occupation And Educational Eye And Face  
Protection, ANSI Standard Z87.1, from American National Standards  
Institute, 1430 Broadway, New York, NY 10018.  
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-  
tion Association, Batterymarch Park, Quincy, MA 02269.  
Cutting And Welding Processes, NFPA Standard 51B, from National  
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.  
1-6. EMF Information  
Considerations About Welding And The Effects Of Low Frequency  
Electric And Magnetic Fields  
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.  
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.  
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 possi-  
ble.  
About Pacemakers:  
To reduce magnetic fields in the workplace, use the following  
procedures:  
Pacemaker wearers consult your doctor first. If cleared by your doctor,  
then following the above procedures is recommended.  
OM-4405 Page 4  
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SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT  
UTILISATION  
rom _nd_fre 11/98  
1-1. Signification des symboles  
SignifieMise 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 signifie Mise en garde ! Soyez vigilant ! Il y a des  
Y
Identifie un message de sécurité particulier.  
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN  
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles  
et aux directives ci-dessous afin de connaître les mesures à prendre pour  
éviter tout danger.  
.
S
i
g
n
i
f
i
e
N
O
T
A
;
n
’
e
s
t
p
a
s
r
e
l
a
t
i
f
à
l
a
s
é
c
u
r
i
t
é
.
1-2. Dangers relatifs au soudage à l’arc  
D
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ  
les pièces endommagées. Entretenir l’appareil conformément à ce  
manuel.  
Y
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 1-5. Veuillez lire et respecter toutes  
ces normes de sécurité.  
D
D
D
Porter un harnais de sécurité quand on travaille en hauteur.  
Maintenir solidement en place tous les panneaux et capots.  
Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec  
la pièce à souder ou la table de travail, le plus près possible de la soudure.  
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact  
D
avec tout objet métallique.  
Y
Y
L’installation, l’utilisation, l’entretien et les réparations ne  
doivent être confiés qu’à des personnes qualifiées.  
Une tension DC importante subsiste à l’intérieur  
des onduleurs après avoir coupé l’alimentation.  
D
Couper l’alimentation du poste et décharger les condensateurs d’entrée  
comme indiqué dans la Section Maintenance avant de toucher des compo-  
sants.  
Au cours de l’utilisation, tenir toute personne à l’écart et plus  
particulièrement les enfants.  
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  
UN CHOC ÉLECTRIQUE peut tuer.  
Un simple contact avec des pièces électriques peut  
provoquer une électrocution ou des blessures graves.  
L’électrode et le circuit de soudage sont sous tension dès  
que l’appareil est sur ON. Le circuit d’entrée et les circuits  
internes de l’appareil sont également sous tension à ce  
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la  
peau. Des étincelles sont projetées pendant le soudage.  
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.  
D
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).  
D
D
Ne jamais toucher les pièces électriques sous tension.  
D
D
D
Porter des protections approuvés pour les oreilles si le niveau sondre est  
trop élevé.  
Porter des gants et des vêtements de protection secs ne comportant pas  
de trous.  
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.  
Porter des vêtements de protection constitué dans une matière durable, ré-  
sistant au feu (laine ou cuir) et une protection des pieds.  
D
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.  
D
D
D
D
Ne pas se servir de source électrique àcourant électrique dans les zones  
humides, dans les endroits confinés ou là où on risque de tomber.  
LES FUMÉES ET LES GAZ peuvent  
être dangereux.  
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le  
procédé de soudage le demande.  
Le soudage génère des fumées et des gaz. Leur inhalation  
peut être dangereux pour votre santé.  
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.  
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).  
D
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.  
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.  
D
D
Installer et mettre à la terre correctement cet appareil conformément à son  
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.  
D
D
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air  
homologué.  
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.  
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.  
D
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.  
D
D
En effectuant les raccordements d’entrée fixer d’abord le conducteur de  
mise à la terre approprié et contre-vérifier les connexions.  
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.  
D
D
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.  
D
D
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 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.  
D
D
Ne pas enrouler les câbles autour du corps.  
Si la pièce soudée doit être mise à la terre, le faire directement avec un  
câble distinct – ne pas utiliser le connecteur de pièce ou le câble de retour.  
D
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou  
une électrode provenant d’une autre machine.  
OM-4405 Page 5  
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LE SOUDAGE peut provoquer un in-  
cendie ou une explosion.  
DES PIÈCES CHAUDES peuvent  
provoquer des brûlures graves.  
D
Prévoir une période de refroidissement avant d’effec-  
tuer des travaux d’entretien.  
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  
D
Porter des gants et des vêtements de protection pour  
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.  
travailler sur un moteur chaud.  
D
Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces  
récemment soudées.  
LE BRUIT peut affecter l’ouïe.  
D
D
D
Se protéger et d’autres personnes de la projection d’étincelles et de métal  
chaud.  
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des  
substances inflammables.  
Le bruit des processus et des équipements peut affecter  
l’ouïe.  
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.  
D
Porter des protections approuvés pour les oreilles si  
le niveau sondre est trop élevé.  
D
Des étincelles et des matériaux chauds du soudage peuvent facilement  
passer dans d’autres zones en traversant de petites fissures et des  
ouvertures.  
LES CHAMPS MAGNÉTIQUES peuvent  
affecter les stimulateurs cardiaques.  
D
D
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.  
D
D
Porteurs de stimulateur cardiaque, restez à distance.  
D
D
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).  
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.  
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.  
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.  
D
D
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.  
D
D
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.  
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des  
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des  
arcs.  
DES PARTICULES VOLANTES  
peuvent blesser les yeux.  
D
D
Placer les bouteilles debout en les fixant dans un support stationnaire ou  
dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.  
D
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-  
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits  
électriques.  
D
D
Ne jamais placer une torche de soudage sur une bouteille à gaz.  
lantes. Pendant la période de refroidissement des soudures, elles ris-  
quent de projeter du laitier.  
Une électrode de soudage ne doit jamais entrer en contact avec une bou-  
teille.  
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.  
D
D
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.  
LES ACCUMULATIONS DE GAZ ris-  
quent de provoquer des blessures ou  
même la mort.  
D
D
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.  
D
Fermer l’alimentation du gaz protecteur en cas de  
non utilisation.  
D
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.  
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-  
rateur d’adduction d’air homologué.  
1-3. Dangers existant en relation avec le moteur  
LE CARBURANT MOTEUR peut pro-  
voquer un incendie ou une explosion.  
LA VAPEUR ET LE LIQUIDE DE  
REFROIDISSEMENT CHAUD peuvent  
provoquer des brûlures.  
D
D
Arrêter le moteur avant de vérifier le niveau de carbu-  
rant ou de faire le plein.  
D
Il est préférable de vérifier le liquide de  
refroidissement une fois le moteur refroidi pour éviter  
de se brûler.  
Ne pas faire le plein en fumant ou proche d’une sour-  
ce d’étincelles ou d’une flamme nue.  
D
D
D
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son  
expansion.  
D
Toujours vérifier le niveau de liquide de refroidissement dans le vase  
d’expansion (si présent), et non dans le radiateur (sauf si précisé autre-  
ment dans la section maintenance du manuel du moteur).  
Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-  
rant renversé avant de faire démarrer le moteur.  
D
D
D
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme  
suivant :  
Jeter les chiffons dans un récipient ignifuge.  
Mettre des lunettes de sécurité et des gants, placer un torchon sur le  
bouchon du radiateur.  
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant  
d’enlever le bouchon.  
OM-4405 Page 6  
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DES ORGANES MOBILES peuvent  
provoquer des blessures.  
L’ACIDE DE LA BATTERIE peut pro-  
voquer des brûlures dans les YEUX et  
sur la PEAU.  
D
Ne pas approcher les mains des ventilateurs, cour-  
roies et autres pièces en mouvement.  
D
D
D
Ne pas renverser la batterie.  
D
Maintenir fermés et fixement en place les portes,  
panneaux, recouvrements et dispositifs de  
protection.  
Remplacer une batterie endommagée.  
Rincer immédiatement les yeux et la peau à l’eau.  
D
D
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’entretien et de dépannage.  
LES GAZ D’ÈCHAPPEMENT DU  
MOTEUR peuvent provoquer des  
accidents mortels.  
D
D
D
Pour empêcher tout démarrage accidentel pendant les travaux d’entre-  
tien, débrancher le câble négatif (–) de batterie de la borne.  
Ne pas approcher les mains, cheveux, vêtements lâches et outils des or-  
ganes mobiles.  
D
Utiliser l’équipement à l’extérieur dans des zones ou-  
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.  
vertes et bien ventilées.  
D
En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappe-  
ment du moteur vers l’extérieur à distance des entrées d’air dans les bâti-  
ments.  
D
D
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise  
en route accidentelle du moteur.  
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention  
sur le générateur.  
LA CHALEUR DU MOTEUR peut pro-  
voquer un incendie.  
L’EXPLOSION DE LA BATTERIE peut  
RENDRE AVEUGLE.  
D
Ne pas placer l’appareil sur, au-dessus ou à proximité  
de surfaces inflammables.  
D
Toujours porter une protection faciale, des gants en  
caoutchouc et vêtements de protection lors d’une in-  
tervention sur la batterie.  
D
Tenir  
à
distance les produits inflammables de  
l’échappement.  
D
D
D
Arrêter le moteur avant de débrancher ou de brancher les câbles de  
batterie.  
LES ÉTINCELLES À L’ÉCHAPPEMENT  
peuvent provoquer un incendie.  
Eviter de provoquer des étincelles avec les outils en travaillant sur la  
batterie.  
Ne pas utiliser le poste de soudage pour charger les batteries ou des vé-  
hicules de démarrage rapide.  
D
D
Empêcher les étincelles d’échappement du moteur  
de provoquer un incendie.  
D
D
Observer la polarité correcte (+ et –) sur les batteries.  
Utiliser uniquement un pare-étincelles approuvé –  
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier  
lieu.  
voir codes en vigueur.  
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement  
et la maintenance  
LA CHUTE DE L’APPAREIL peut  
blesser.  
L’EMPLOI EXCESSIF peut  
SURCHAUFFER L’ÉQUIPEMENT.  
D
D
Utiliser l’anneau de levage uniquement pour soulever  
l’appareil lui-même ; sans chariot, de bouteilles de  
gaz, remorque, ou autres accessoires.  
D
D
D
Laisser l’équipement refroidir ; respecter le facteur de  
marche nominal.  
Réduire le courant ou le facteur de marche avant de  
poursuivre le soudage.  
Utiliser un équipement de levage de capacité suffi-  
sante pour lever l’appareil.  
Ne pas obstruer les passages d’air du poste.  
D
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.  
LES  
CHARGES  
peuvent  
ÉLECTROSTATIQUES  
LES ÉTINCELLES VOLANTES ris-  
quent de provoquer des blessures.  
endommager les circuits imprimés.  
D
Établir la connexion avec la barrette de terre avant de  
manipuler des cartes ou des pièces.  
D
Porter un écran facial pour protéger le visage et les  
yeux.  
D
Utiliser des pochettes et des boîtes antistatiques  
pour stocker, déplacer ou expédier des cartes de  
circuits imprimes.  
D
D
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.  
UNE REMORQUE QUI BASCULE peut  
entraîner des blessures.  
Les étincelles risquent de causer un incendie – éloigner toute substance  
inflammable.  
D
D
Utiliser les supports de la remorque ou des blocs  
pour soutenir le poids.  
LE SURCHAUFFEMENT peut endom-  
mager le moteur électrique.  
Installer convenablement le poste sur la remorque  
comme indiqué dans le manuel s’y rapportant.  
D
Arrêter ou déconnecter l’équipement avant de dé-  
marrer ou d’arrêter le moteur.  
LIRE LES INSTRUCTIONS.  
D
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.  
D
D
Utiliser seulement les pièces de rechange d’origine.  
Effecteur la maintenance et la mise en service  
D
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a  
d’après le manuel et celui du moteur.  
lieu.  
OM-4405 Page 7  
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LE RAYONNEMENT HAUTE FRÉ-  
QUENCE (H.F.) risque de provoquer  
des interférences.  
LE SOUDAGE À L’ARC risque de  
provoquer des interférences.  
D
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.  
D
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.  
D
D
Veiller à ce que tout l’équipement de la zone de soudage soit compatible  
électromagnétiquement.  
D
D
Demander seulement à des personnes qualifiées familiarisées avec des  
équipements électroniques de faire fonctionner l’installation.  
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).  
L’utilisateur est tenu de faire corriger rapidement par un électricien quali-  
fié les interférences résultant de l’installation.  
D
D
D
Veiller à souder à une distance de 100 mètres de tout équipement élec-  
tronique sensible.  
D
D
D
Si le FCC signale des interférences, arrêter immédiatement l’appareil.  
Effectuer régulièrement le contrôle et l’entretien de l’installation.  
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformé-  
ment à ce mode d’emploi.  
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.  
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.  
1-5. Principales normes de sécurité  
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Weld-  
ing Society, 550 N.W. Lejeune Rd, Miami FL 33126  
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,  
de la Compressed Gas Association, 1235 Jefferson Davis Highway,  
Suite 501, Arlington, VA 22202.  
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent  
of Documents, U.S. Government Printing Office, Washington, D.C.  
20402.  
Règles de sécurité en soudage, coupage et procédés connexes, norme  
CSA W117.2, de l’Association canadienne de normalisation, vente de  
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.  
RecommendedSafe Practice for the Preparation for Welding and Cut-  
ting of Containers That Have Held Hazardous Substances, norme AWS  
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL  
33126  
Safe Practices For Occupation And Educational Eye And Face Protec-  
tion, norme ANSI Z87.1, de l’American National Standards Institute,  
1430 Broadway, New York, NY 10018.  
NationalElectrical Code, NFPA Standard 70, de la National Fire Protec-  
tion Association, Batterymarch Park, Quincy, MA 02269.  
Cutting and Welding Processes, norme NFPA 51B, de la National Fire  
Protection Association, Batterymarch Park, Quincy, MA 02269.  
1-6. Information sur les champs électromagnétiques  
Données sur le soudage électrique et sur les effets, pour l’organisme,  
des champs magnétiques basse fréquence  
Afin de réduire les champs électromagnétiques dans l’environnement  
de travail, respecter les consignes suivantes :  
1
Garder les câbles ensembles en les torsadant ou en les  
attachant avec du ruban adhésif.  
Le courant de soudage, pendant son passage dans les câbles de sou-  
dage, causera des champs électromagnétiques. Il y a eu et il y a encore  
un certain souci à propos de tels champs. Cependant, après avoir ex-  
aminé plus de 500 études qui ont été faites pendant une période de  
recherche de 17 ans, un comité spécial ruban bleu du National Re-  
search Council a conclu: “L’accumulation de preuves, suivant le  
jugement du comité, n’a pas démontré que l’exposition aux champs  
magnétiqueset champs électriques à haute fréquence représente un  
risque à la santé humaine”. Toutefois, des études sont toujours en cours  
et les preuves continuent à être examinées. En attendant que les con-  
clusions finales de la recherche soient établies, il vous serait  
souhaitablede réduire votre exposition aux champs électromagnéti-  
ques pendant le soudage ou le coupage.  
2
3
Mettre tous les câbles du côté opposé de l’opérateur.  
Ne pas courber pas et ne pas entourer pas les câbles autour de  
votre corps.  
4
5
Garder le poste de soudage et les câbles le plus loin possible de  
vous.  
Relier la pince de masse le plus près possible de la zone de  
soudure.  
Consignes relatives aux stimulateurs cardiaques :  
Les personnes qui portent un stimulateur cardiaque doivent avant tout  
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est  
alors recommandé de respecter les consignes ci–dessus.  
OM-4405 Page 8  
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SECTION 2 – DEFINITIONS  
2-1. Symbols And Definitions  
Fast (Run, Weld/  
Power)  
Stop Engine  
Slow (Idle)  
Start Engine  
Engine Oil  
Air Temperature Or  
Engine  
Engine Oil  
Pressure  
Battery (Engine)  
Temperature  
Check Valve  
Clearance  
Protective Earth  
(Ground)  
Engine  
Fuel  
Certified/Trained  
Mechanic  
Positive  
Negative  
Welding Arc  
Remote  
Amperes  
Volts  
Panel/Local  
Output  
A V  
Electrode  
Alternating  
Current  
Work Connection  
Connection  
Stick (SMAW)  
Welding  
Constant Current  
(CC)  
MIG (GMAW)  
Welding  
TIG (GTAW)  
Single Phase  
Time  
Hours  
Seconds  
1
h
s
Read Operator’s  
Do Not Switch  
While Welding  
Three Phase  
Engine Choke  
Circuit Breaker  
Hertz  
3
Manual  
Contactor On  
Hz  
SECTION 3 – SPECIFICATIONS  
3-1. Weld, Power, And Engine Specifications  
Maximum  
Welding  
Mode  
Weld Output  
Range  
Rated Welding  
Output  
Open-  
Circuit  
Voltage  
Fuel  
Capacity  
Auxiliary Power Rating  
Engine  
Standard  
Single-Phase,  
4 kVA/kW, 34/17 A,  
120/240 V AC,  
50/60 Hz  
45 – 500 A  
(CC Models)  
95  
56  
CC/DC  
CV/DC  
.
300 A, 40 Volts DC,  
100% Duty Cycle  
Wis Con  
15 – 500 A  
(CC/CV Models)  
Wis-Con TM-20  
Water-Cooled,  
Three-Cylinder,  
38 HP Gasoline  
Engine  
400 A, 40 Volts DC,  
60% Duty Cycle  
25 gal  
(95 L)  
Full kVA Option*  
Single-Phase/Three-Phase,  
12/15 kVA/kW, 50/36A,  
120/240 VAC, 60 Hz  
500 A, 30 Volts DC,  
40% Duty Cycle  
(CC/CV  
Models  
Only)  
14 – 40 V  
*In Addition To Standard  
4 kVA/kW Auxiliary Power  
OM-4405 Page 9  
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3-2. Dimensions, Weights, And Operating Angles  
Dimensions  
58 in (1473 mm)  
(to top of muffler)  
G
Height  
Width  
28-1/2 in (724 mm)  
(mtg. brackets turned in)  
Y
Y
Do not exceed tilt angles or engine could  
be damaged or unit could tip.  
Do not move or operate unit where it could  
tip.  
30-3/4 in (781 mm)  
(mtg. brackets turned out)  
Depth  
64-7/16 in (1637 mm)  
64-7/16 in (1637 mm)  
55-7/8 in (1419 mm)  
46-3/8 in (1178)  
A
B
C
D
E
F
A
B
C
D
9-1/2 in (241 mm)  
27-1/2 in (699 mm)  
1 in (25 mm)  
30°  
H
30°  
20°  
G
29-1/2 in (743 mm)  
Front Panel End  
E
20°  
9/16 in (14 mm) Dia.  
4 Holes  
H
F
Weight  
No fuel: 1600 lb (726 kg)  
w/fuel: 1775 lb (805 kg)  
802 161-A  
802 729  
3-3. 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  
80  
60  
40  
20  
0
Ranges  
210 – Max  
165 – 350  
100 – 250  
65 – 120  
45 – 85  
0
100  
200  
300  
400  
500  
600  
700  
DC AMPERES  
202 666-A  
OM-4405 Page 10  
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3-4. 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  
80  
60  
40  
20  
0
0
100  
200  
300  
400  
500  
600  
700  
800  
900  
DC AMPERES  
B. MIG Mode  
100  
80  
60  
40  
MAX  
20  
MIN  
0
0
100 200 300 400 500 600 700 800 900 1000  
DC AMPERES  
C. TIG Mode  
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
0
Ranges  
50 – 335  
40 – 240  
25 – 150  
15 – 75  
0
50  
100 150 200 250 300 350 400 450 500  
DC AMPERES  
202 655 / 202 656 / 202 654  
OM-4405 Page 11  
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3-5. Fuel Consumption  
The curve shows typical fuel use  
under weld or power loads.  
2.50  
2.25  
2.00  
1.75  
1.50  
1.25  
1.00  
0.75  
IDLE  
0.50  
0.25  
0.00  
0
50  
100  
150  
200  
250  
300  
350  
400  
DC WELD AMPERES AT 100% DUTY CYCLE  
201 033  
3-6. 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  
Y
Exceeding duty cycle can  
damage unit and void  
warranty.  
ContinuousWelding  
% DUTY CYCLE  
199 140  
OM-4405 Page 12  
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3-7. AC Auxiliary Power Curve  
The ac power curve shows the aux-  
iliary power in amperes available at  
the 120 and 240 volt receptacles.  
150 300  
125 250  
100 200  
75 150  
50 100  
25 50  
0
0
0
0
5
10  
15  
20  
25  
50  
30  
60  
AC AMPERES IN 240V MODE  
10  
20 30 40  
AC AMPERES IN 120V MODE  
193 018  
3-8. Optional AC Power Plant Curves  
The ac power curves show the aux-  
iliary 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 Auxiliary Power Plant (No Weld Load)  
280  
260  
240  
220  
200  
180  
0
20  
40  
60  
80  
100  
AC AMPERES  
B. 15 kVA/kW Three-Phase Auxiliary Power Plant (No Weld Load)  
280  
260  
240  
220  
200  
180  
0
10  
20  
30  
40  
50  
60  
70  
AC AMPERES  
198 868 /98 869  
OM-4405 Page 13  
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SECTION 4 – INSTALLATION  
4-1. Installing Welding Generator (See Sections 4-2 And 4-3)  
Movement  
Airflow Clearance  
Location  
18 in  
(460 mm)  
18 in  
(460 mm)  
18 in  
(460 mm)  
OR  
OR  
18 in  
(460 mm)  
18 in  
(460 mm)  
Y
Y
Always securely fasten  
welding generator onto  
transport vehicle or trailer  
and comply with all DOT and  
other applicable codes.  
Grounding  
3
1
4
Always ground generator  
frame to vehicle frame to pre-  
vent electric shock and static  
electricityhazards.  
GND/PE  
OR  
1
2
3
Generator Base  
Metal Vehicle Frame  
Equipment Grounding  
Terminal  
Electrically bond generator frame to  
vehicle frame by metal-to-metal  
contact.  
4
Grounding Cable  
Use #10 AWG or larger insulated  
copper wire.  
2
2
Y
If unit does not have GFCI re-  
ceptacles, use GFCI-  
protected extension cord.  
install2 1/01 – Ref. 800 652 / Ref. 800 477-A / 158 936-A / 0854  
4-2. Using Lifting Eye  
1
2
3
Lifting Eye  
Nut  
1
Carriage Bolt  
Raise lifting eye until it snaps in  
place. Lower lifting eye when not  
needed.  
. To lock the lifting eye in the up-  
right 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).  
2
3
Tools Needed:  
Ref. 802 729  
OM-4405 Page 14  
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4-3. Mounting Welding Generator  
Y
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.  
1
1
2
Mounting Bracket  
1/2 in Bolt And Washer (Not  
Supplied)  
3
3/8-16 x 1 in Screws  
(Supplied)  
To Bolt Unit In Place:  
Remove hardware securing the  
four mounting brackets to the base.  
Reverse brackets and reattach to  
base with original hardware.  
Welding Unit In Place  
Bolting Unit In Place  
Mount unit to truck or trailer with 1/2  
in (12 mm) hardware (not supplied).  
2
1
To Weld Unit In Place:  
Weld unit to truck or trailer only at  
the four mounting brackets.  
3
Tools Needed:  
9/16 in  
Ref. 190 250-A / Ref. 802 730  
4-4. Installing Exhaust Pipe  
Y
Y
Stop engine and let cool.  
Engine backfire can cause se-  
vere burns or other injuries. Do  
not point exhaust pipe toward  
control panel. Keep away from  
exhaust outlet.  
. Point exhaust pipe in desired di-  
rection but always away from  
front panel and direction of travel.  
Tools Needed:  
1/2 in  
Ref. 802 730 / Ref. 201 841  
OM-4405 Page 15  
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4-5. Activating The Dry Charge Battery (If Applicable)  
Remove battery from unit.  
1
Eye Protection – Safety  
Glasses Or Face Shield  
2
3
4
Rubber Gloves  
Vent Caps  
5
Sulfuric Acid Electrolyte  
(1.265 Specific Gravity)  
5
Well  
4
1
Fill each cell with electrolyte to  
bottom of well (maximum).  
3
Y
Do not overfill battery cells.  
Wait ten minutes and check electro-  
lyte level. If necessary, add electro-  
lyte to raise to proper level. Reins-  
tall vent caps.  
6
Battery Charger  
Y
Read and follow all instruc-  
tions supplied with battery  
charger.  
2
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.  
6
5 A For 30 Minutes  
OR  
Tools Needed:  
+
–
rubber gloves  
30 A For 12 Minutes  
glasses  
drybatt1 1/98 – 0886  
OM-4405 Page 16  
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4-6. Connecting The Battery  
Y
Connect Negative (–) Cable Last.  
+
–
Tools Needed:  
1/2 in  
802 168-B / Ref. 201 841 / 802 313 / S-0756-C  
Notes  
OM-4405 Page 17  
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4-7. Engine Prestart Checks  
Check radiator coolant level when  
fluid is low in recovery tank.  
Full  
Capacity: 9 qt (8.5L)  
Full  
Gasoline  
Full  
Coolant Recovery Tank  
Hot Full  
Cold Full  
802 731  
time (see engine maintenance label for fuel  
specifications).  
Engine coolant is a mixture of water and  
ethylene glycol base antifreeze. Add anti-  
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.  
.
C
h
e
c
k
a
l
l
e
n
g
i
n
e
f
l
u
i
d
s
d
a
i
l
y
.
Engine must be cold and on a level surface.  
Unit is shipped with 20W break-in oil.  
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).  
Automaticshutdown system stops engine if  
oil pressure is too low, or coolant tempera-  
ture is too high.  
Y
Incorrect engine temperature can  
damage engine. Do not run engine  
without a properly working thermo-  
stat and radiator cap.  
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.  
.
T
h
i
s
u
n
i
t
h
a
s
a
l
o
w
o
i
l
p
r
e
s
s
u
r
e
s
h
u
t
-
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.  
.
T
o
i
m
p
r
o
v
e
c
o
l
d
w
e
a
t
h
e
r
s
t
a
r
t
i
n
g
:
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.  
Keep battery in good condition. Store  
battery in warm area off concrete sur-  
face.  
Follow run-in procedure in engine manual.  
Fuel  
Use correct grade oil for cold weather  
(see Section 8-1).  
Add fresh fuel before starting engine the first  
OM-4405 Page 18  
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4-8. Connecting To Weld Output Terminals  
Y
1
Stop engine.  
Tools Needed:  
3/4 in  
Positive (+) Weld Output Terminal  
Negative (–) Weld Output Terminal  
2
For Stick and TIG welding Direct Current  
Electrode Positive (DCEP), connect  
electrodeholder cable to Positive (+) ter-  
minal 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,  
connect electrode holder cable to Elec-  
trode terminal on left and work cable to  
Work terminal on right.  
For MIG and FCAW welding Direct Cur-  
rent Electrode Positive (DCEP) on CC/  
CV models, connect wire feeder cable to  
Positive (+) terminal on left and work  
cable to Negative (–) terminal on right.  
Use Process/Contactor switch to select  
type of weld output (see Section 6-3).  
1
For Direct Current Electrode Negative  
(DCEN), reverse cable connections.  
If equipped with optional polarity switch,  
connect wire feeder cable to Electrode  
terminal on left and work cable to Work  
2
terminal on right.  
802 729  
4-9. 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  
Y
Y
Stop engine before  
connectingto weld out-  
put terminals.  
10 – 60% 60 – 100%  
Welding  
Amperes  
Duty  
Duty  
10 – 100% Duty Cycle  
Cycle  
Cycle  
Do not use worn, dam-  
aged, undersized, or  
poorly spliced cables.  
100  
150  
200  
4 (20)  
3 (30)  
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 (50)  
1/0 (60)  
2/0 (70)  
3/0 (95)  
3/0 (95)  
4/0 (120)  
2/0 (70)  
3/0 (95) 4/0 (120)  
(2x70)  
(2x70)  
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0  
(2x70) (2x95) (2x95)  
1/0 (60)  
2/0 (70)  
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)  
1/0 (60)  
2/0 (70)  
4/0 (120)  
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  
2
S-0007-E–  
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.  
OM-4405 Page 19  
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4-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models  
1
Remote Amperage Adjust  
Receptacle RC13  
Connect optional remote control to  
RC13 (see Section 5-3).  
1
Ref. 154 862-A / 048 720-K / 802 729  
OM-4405 Page 20  
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4-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models  
Socket*  
Socket Information  
A
24 volts ac. Protected by circuit  
breaker CB5.  
24 VOLTS AC  
B
Contact closure to A completes  
24 volt ac contactor control  
circuit.  
C
Output to remote control:+10  
volts dc in MIG or Stick mode;  
0 to +10 volts dc in TIG mode.  
New! LDR-14 long  
distance remote  
(includes 120 V  
receptacle)  
D
Remote control circuit common.  
REMOTE  
OUTPUT  
CONTROL  
E
DC input command signal: 0 to  
+10 volts from min. to max. of  
remote control with Voltage/  
Amperage Adjust control at  
max.  
OR  
K
Chassis common.  
GND  
802 729  
NEUTRAL  
G
Circuit common for 24 volt ac  
circuit.  
*The remaining sockets are not used.  
OM-4405 Page 21  
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SECTION 5 – OPERATING WELDING GENERATOR – CC MODELS  
5-1. Front Panel Controls For CC Models (See Section 5-2)  
5
4
6
7
13  
14  
18  
19  
10 11  
12  
9
8
2
1
3
15  
16  
17  
201 841 / 802 729  
OM-4405 Page 22  
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5-2. Description Of Front Panel Controls For CC Models (See Section 5-1)  
Engine Starting Controls  
Magnetic Shutdown Switch  
8
Engine Hour Meter  
amperagerange possible to help prevent arc  
outages.  
1
Engine Gauges  
14 AmperageAdjust Control  
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.  
. To read gauges and engine indicator  
lights with engine off, turn Engine Control  
switch to Run/Idle and press Magnetic  
Shutdown switch (see Section 8-10).  
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).  
2
Starting Aid (Engine Choke Control)  
Use control to change engine air-fuel mix.  
Engine Control Switch  
9
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.  
3
To check fuel level when engine is not run-  
ning, turn Engine Control switch to Run/Idle  
position and press Magnetic Shutdown  
switch.  
Use switch to start engine, select engine  
speed, and stop engine.  
15 Stick/TIG Selection Switch  
In Run position, engine runs at weld/power  
speed. In Run/Idle position, engine runs at  
idle speed at no load and weld speed with load  
applied.  
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).  
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.  
To Start:  
When switch is in the Stick position, the max  
OCV circuit resets Amperage Adjust Control  
R1 to maximum when the arc breaks.  
. If engine does not start, let engine come  
to a complete stop before attempting re-  
start.  
Also in the Stick position, the arc drive (dig)  
circuit provides additional amperage during  
low voltage (short arc length conditions) to  
prevent “sticking” electrodes.  
11 Engine Coolant Temperature Gauge  
(Optional)  
Pull Choke control out. 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.  
Push Choke control in.  
Normal temperature is 180 - 203° F (82 - 95°  
C). When equipped with gauge option, engine  
stops if temperature exceeds 220° F (104° C).  
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.  
12 Engine Oil Pressure Gauge (Optional)  
To Stop: turn Engine Control switch to Off Normal pressure is 30 – 80 psi (207 – 552  
16 Amperage Adjust Switch And Remote  
Amperage Adjust Receptacle  
position.  
kPa). When equipped with gauge option, en-  
gine stops if pressure is below 10 psi (69  
kPa).  
Engine Indicator Lights  
Connect optional remote control to RC13  
(See Section 4-10). 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 4-10 and 5-3).  
4
Battery Charging Light  
Weld Controls  
Light goes on if engine alternator is not charg-  
ing battery. Engine continues to run.  
. Max OCV Control Circuit: This unit has  
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.  
Y
Stop engine and fix trouble if Battery  
Charging light goes on.  
5
Engine Temperature Light  
17 Polarity Switch (Optional)  
Light goes on and engine stops if engine tem-  
perature is above 230 ° F (110° C).  
Y
Do not switch under load.  
Y
Stop engine and fix trouble if Engine  
Temperature light goes on.  
Use switch to change weld output. Select ei-  
ther DC Electrode Positive (DCEP) or DC  
Electrode Negative (DCEN).  
6
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.  
Weld Meters  
The max OCV circuit is disabled when  
the Stick/TIG Selection switch is in  
Scratch Start TIG position (see item 15).  
18 DC Voltmeter (Optional)  
Voltmeterdisplays voltage at the weld output  
terminals, but not necessarily the welding arc  
due to resistance of cable and connections.  
Y
Stop engine and fix trouble if Engine  
Oil Pressure light stays on after start-  
up.  
13 Ampere Range Switch  
Y
Do not switch under load.  
19 DC Ammeter (Optional)  
7
Fuel Light  
Use switch to select weld amperage range. Ammeter displays amperage output of the  
For most welding applications, use lowest unit.  
Fuel light is not active on this model.  
OM-4405 Page 23  
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5-3. Remote Amperage Control On CC Models (Optional)  
1
Remote Amperage Adjust  
Receptacle RC13  
Connect optional remote control to  
RC13 (see Section 4-10).  
1
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  
0774 / Ref. 154 862-A / Ref. 181 711-A / 802 729  
OM-4405 Page 24  
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Notes  
OM-4405 Page 25  
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SECTION 6 – OPERATING WELDING GENERATOR – CC/CV MODELS  
6-1. Front Panel Controls For CC/CV Models (See Section 6-2)  
5
6
4
7
14  
15  
18  
19  
10 11  
12  
9
8
2
1
3
13  
16  
17  
201 579 / 802 729  
OM-4405 Page 26  
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6-2. Description Of Front Panel Controls For CC/CV Models (See Section 6-1)  
Engine Starting Controls  
Magnetic Shutdown Switch  
tarily during start-up but goes out when en- Use the lowest four ranges for Stick and TIG  
gine reaches normal oil pressure.  
welding. Read the upper set of numbers at  
each range for Stick welding and the lower set  
at each range for TIG welding.  
1
Y
Stop engine and fix trouble if Engine  
Oil Pressure light stays on after start-  
up.  
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.  
Use the highest range for MIG welding and for  
cutting and gouging (CAC-A).  
7
Fuel Light  
For most welding applications, use lowest  
amperagerange possible to help prevent arc  
outages.  
Fuel light is not active on this model.  
Engine Hour Meter  
2
Starting Aid (Engine Choke Control)  
Use control to change engine air-fuel mix.  
Engine Control Switch  
8
Engine Gauges  
15 Voltage/AmperageAdjust Control  
3
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-  
peragein TIG mode, but has no effect in Stick  
and MIG modes.  
. To read gauges and engine indicator  
lights with engine off, turn Engine Control  
switch to Run/Idle and press Magnetic  
Shutdown switch (see Section 8-10).  
Use switch to start engine, select engine  
speed, and stop engine.  
In Run position, engine runs at weld/power  
speed. In Run/Idle position, engine runs at  
idle speed at no load and weld speed with load  
applied.  
9
Fuel Gauge  
Use gauge to check fuel level.  
To Start:  
To check fuel level when engine is not run-  
ning, turn Engine Control switch to Run/Idle  
position and press Magnetic Shutdown  
switch.  
. If engine does not start, let engine come  
to a complete stop before attempting re-  
start.  
Weld output would be about 213 A DC with  
controls set as shown (50% of 110 to 315 A).  
10 Battery Voltmeter (Optional)  
. The numbers around the control are for  
reference only and do not represent an  
actual percentage value.  
Pull Choke control out. 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.  
Push Choke control in.  
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.  
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 4-11 and 6-4).  
11 Engine Coolant Temperature Gauge  
(Optional)  
To Stop: turn Engine Control switch to Off  
position.  
Normal temperature is 180 - 203° F (82 - 95°  
C). When equipped with gauge option, engine  
stops if temperature exceeds 220° F (104° C).  
Engine Indicator Lights  
4
Battery Charging Light  
17 Polarity Switch (Optional)  
12 Engine Oil Pressure Gauge (Optional)  
Light goes on if engine alternator is not charg-  
ing battery. Engine continues to run.  
Y
Do not switch under load.  
Normal pressure is 30 – 80 psi (207 – 552  
kPa). When equipped with gauge option, en-  
gine stops if pressure is below 10 psi (69  
kPa).  
Use switch to change weld output. Select ei-  
ther DC Electrode Positive (DCEP) or DC  
Electrode Negative (DCEN).  
Y
Stop engine and fix trouble if Battery  
Charging light goes on.  
5
Engine Temperature Light  
Weld Meters  
Weld Controls  
Light goes on and engine stops if engine tem-  
perature is above 230 ° F (110° C).  
18 DC Voltmeter (Optional)  
13 Process/Contactor Switch  
Voltmeterdisplays voltage at the weld output  
terminals, but not necessarily the welding arc  
due to resistance of cable and connections.  
See Section 6-3 for Process/Contactor  
switch information.  
Y
Stop engine and fix trouble if Engine  
Temperature light goes on.  
14 Ampere Range Switch  
6
Engine Oil Pressure Light  
19 DC Ammeter (Optional)  
Y
Do not switch under load.  
Light goes on and engine stops if oil pressure  
Ammeter displays amperage output of the  
unit.  
is below 5 psi (34 kPa). Light goes on momen- Use switch to select weld amperage range.  
OM-4405 Page 27  
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6-3. Process/Contactor Switch On CC/CV Models  
1
Process/Contactor Switch  
Y
Weld output terminals are en-  
ergized when Process/Con-  
tactor switch is in an Electrode  
Hot position and the engine is  
running.  
1
Use switch to select weld process  
and weld output on/off control (see  
table below and Section 6-4).  
Place switch in Remote positions to  
turn weld output on and off with a de-  
vice connected to the remote 14 re-  
ceptacle.  
Place switch in Electrode Hot posi-  
tions for weld output to be on whenev-  
er the engine is running.  
Use Stick position for air carbon arc  
(CAC-A) cutting and gouging.  
When switch is in a Stick position, the  
arc drive (dig) circuit provides addi-  
tional amperage during low voltage  
(short arc length conditions) to pre-  
vent “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 option-  
al auxiliary power plant (see Sec-  
tion 7-2).  
. The engine auto idle function  
does not work in the Remote-TIG  
mode.  
Process/Contactor Switch Settings  
Switch Setting  
Process  
Output On/Off Control  
Engine Auto Idle  
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  
At Remote 14 Receptacle  
Electrode Hot  
Active  
Active  
Active  
Electrode Hot – MIG  
MIG (GMAW)  
Stick (SMAW),  
Air Carbon Arc (CAC-A) Cutting  
And Gouging  
Electrode Hot – Stick  
Electrode Hot  
Electrode Hot  
Active  
Active  
Electrode Hot – Scratch  
Scratch Start TIG (GTAW)  
Start TIG  
OM-4405 Page 28  
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6-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)  
1
Remote 14 Receptacle RC14  
Connect optional remote control to  
RC14 (see Section 4-11).  
1
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 / 802 730  
OM-4405 Page 29  
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SECTION 7 – OPERATING AUXILIARY EQUIPMENT  
7-1. 120 Volt And 240 Volt Receptacles  
1
2
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.  
1
2
3
4
. At least once a month, run en-  
gine at weld/power speed and  
press test button to verify GFCI  
is working properly.  
3
4
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.  
.
A
u
x
i
l
i
a
r
y
p
o
w
e
r
i
s
n
o
t
a
f
f
e
c
t
e
d
by weld output.  
Maximum output is 2.4 kVA/kW  
from GFCI1 and 4 kVA/kW from  
RC1. Maximum output from all re-  
ceptacles is 4 kVA/kW.  
EXAMPLE: If 13 A is drawn from  
RC1, only 7 A is available at GFCI1:  
(240 V x 13 A) + (120 V x 7 A) =  
4.0 kVA/kW  
191 624-A  
OM-4405 Page 30  
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7-2. Connecting To Optional Auxiliary Power Plant (CC/CV Models Only)  
.
P
l
a
c
e
P
r
o
c
e
s
s
/
C
o
n
t
a
c
t
o
r
s
w
i
t
c
h
in Electrode Hot - Stick position  
when using auxiliary power plant  
(see Section 6-3).  
1
2
Single-Phase Power Connection  
Single-Phase Auxiliary Power  
1
120/240 V 50 A Receptacle  
RC5  
RC5 is connected to the optional  
auxiliary power plant and supplies 60  
Hz single-phase power at weld/pow-  
er speed. Maximum output from RC5  
is 12 kVA/kW. Power available at  
RC5 is reduced when welding.  
2
Circuit Breaker CB7  
Circuit breaker CB7 protects single-  
phase receptacle RC5 and the load  
wires from overload. If CB7 opens, all  
auxiliary power plant output stops  
and the receptacle does not work.  
Three-Phase Auxiliary Power  
Three-Phase Power Connection  
Single  
Phase  
1
Three  
Phase  
3
AC  
Y
Y
Stop engine.  
Output  
Power and weld outputs are  
live at the same time. Discon-  
nect or insulate unused  
cables.  
Volts  
120/240  
240  
Y
Close panel opening  
if no connections are  
made to power plant.  
Amps  
KVA/KW  
50  
12  
48  
20  
Frequency  
Engine Speed  
60 Hz  
1850 RPM  
. Have qualified person install ac-  
cording to circuit diagram and  
Auxiliary Power Guidelines (see  
Section 10).  
Lead 42 connects to GROUND stud on  
front of unit.  
Remove auxiliary power panel  
mountingscrews. Tilt panel forward.  
Jumper 42 is connected to 90 at factory.  
93  
3
4
5
6
Lead 93  
Lead 92  
Lead 91  
91  
Remove plug  
before inserting  
leads. Reinstall  
bushing.  
90  
92  
Lead 42 (Circuit Grounding  
Lead)  
7
8
9
Lead 90 (Neutral)  
4
3
Rear Of Panel  
Isolated Neutral Terminal  
Jumper Lead 42  
5
6
91  
92  
93  
10 Grounding Terminal  
2
Jumper 42 is connected to lead 90 at  
factory. Jumper 42 may be discon-  
nected from neutral to meet applica-  
ble electrical codes.  
12  
7
Lead 42 connects to front panel  
Ground stud.  
10  
11 User-Supplied Leads  
12 Circuit Breaker CB7 User  
Terminals  
11  
Connect user-supplied leads to ter-  
minals on CB7 and to the isolated  
neutral terminal and grounding termi-  
nal as necessary.  
Y
Close  
panel  
opening if no  
connections  
are made to  
power plant.  
9
8
. Circuit breaker CB7 protects  
single-phase receptacle RC5  
and the load wires from overload.  
If CB7 opens, all auxiliary power  
plant output stops and the recep-  
tacle does not work.  
240V  
240V  
120V  
1-Phase  
3-Phase  
120V  
Tools Needed:  
240V  
Reinstall auxiliary power panel.  
240V  
Ref. 197 399 / 802 332-E  
OM-4405 Page 31  
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7-3. Optional Auxiliary Power Receptacles  
1
2
3
4
120 V 20 A AC GFCI  
Receptacle GFCI1  
240 V 16 A AC European  
Receptacle RC1  
European Receptacle  
1
2
240 V 15 A AC Australian  
Receptacle RC1  
5
240 V 15 A AC South African  
Receptacle RC1  
6
Receptacles supply 60 Hz single-  
phase power at weld/power speed.  
If a ground fault is detected, the  
GFCI Reset button pops out and  
the receptacle does not work.  
Check for faulty tools plugged in  
receptacle. Press button to reset  
GFCI1.  
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gine at weld/power speed and  
press test button to verify GFCI  
is working properly.  
Australian Receptacle  
1
3
5
6
Circuit Breaker CB2  
Circuit Breaker CB3  
5
CB2 protects GFCI1 from overload.  
If CB2 opens, GFCI1 does not  
work. Place button to reset breaker.  
6
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.  
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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  
1
4
5
EXAMPLE: If 13 A is drawn from  
RC1, only 7 A is available at GFCI1:  
6
(240 V x 13 A) + (120 V x 7 A) =  
4.0 kVA/kW  
191 624  
OM-4405 Page 32  
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SECTION 8 – MAINTENANCE & TROUBLESHOOTING  
8-1. Maintenance Label  
OM-4405 Page 33  
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8-2. Routine Maintenance  
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an  
extended period.  
Note  
Y
Stop engine before maintaining.  
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Recycle engine  
fluids.  
nance Label. Service unit more often if  
used in severe conditions.  
*
To be done by Factory Authorized  
Service Agent.  
8 h  
Coolant  
Full  
Check Fluid  
Levels. See  
Section 4-7.  
Wipe  
Up  
Spills.  
OIL  
Full  
50 h  
Clean And  
Tighten  
Weld  
Check Belt  
Tension.  
1/2 in.  
(13 mm)  
Clean Air Filter.  
See Section 8-4.  
Terminals.  
100 h  
Change Oil  
Filter. See  
Section 8-8.  
Change Oil. See  
Section 8-8.  
Clean And  
Tighten  
Battery  
Replace fuel  
filter. See  
Section 8-8.  
Connections.  
Check air cleaner hoses  
for cracks and loose  
clamps.  
250 h  
Check And  
Clean Spark  
Arrestor. See  
Section 8-3.  
Check  
Spark  
Plugs.  
Replace  
Unreadable  
Labels.  
OM-4405 Page 34  
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500 h  
Repair Or  
Replace  
Damaged  
Cables.  
Check  
Valve  
Clearance.*  
1000 h  
Blow Out Or  
Vacuum Inside.  
During Heavy  
Service,  
Drain Sludge  
From Fuel  
Tank. See  
FUEL  
OR  
SLUDGE  
Section 8-8.  
Clean Monthly.  
Service Welding Generator  
Brushes And Slip Rings. Service  
More Often In Dirty Conditions.*  
8-3. Inspecting And Cleaning Optional Spark Arrestor Muffler  
Y
1
Stop engine and let cool.  
Spark Arrestor Muffler  
Cleanout Plug  
2
Remove plug and remove any dirt  
covering cleanout hole.  
3
Exhaust Pipe  
Start engine and run at idle speed to  
blow out cleanout hole. If nothing  
blows out of hole, briefly cover end  
of exhaust pipe with fireproof  
material.  
3
2
1
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Stop engine and let cool.  
Reinstall cleanout plug.  
Tools Needed:  
3/8 in  
802 729 / Ref. 201 841  
OM-4405 Page 35  
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8-4. Servicing Air Cleaner  
Y
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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.  
1
3
4
2
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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.  
5
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.  
1
2
3
4
5
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  
Y
Do not clean housing with air  
hose.  
Clean primary element with compressed  
air only.  
Air pressure must not exceed 100 psi  
(690 kPa). Use 1/8 in (3 mm) nozzle and  
keep nozzle at least 2 in (51 mm) from  
inside of element. Replace primary ele-  
ment if it has holes or damaged gaskets.  
Reinstall primary element and cap (dust  
ejector down).  
aircleaner1 9/00 – 153 929-B / 153 585 / Ref. S-0698-B  
OM-4405 Page 36  
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8-5. Adjusting Engine Weld/Power Speed  
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Stop engine and let cool.  
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quire adjustment if engine  
speed is adjusted (see Section  
8-7).  
Engine Speed  
(No Load)  
RPM (Hz)  
Engine speed is factory set and  
should not require adjustment. Af-  
ter tuning engine, check engine  
speed with tachometer or frequen-  
cy meter. See table for proper no  
load speed. If necessary, adjust  
speed as follows:  
1850 (61.7)  
Maximum  
Weld/Power  
Start engine and run until warm.  
7
On CC Models, place Stick/TIG  
switch in Stick position.  
11  
10  
On CC/CV models, turn Process/  
Contactor switch to Stick – Elec-  
trode Hot position.  
9
1
2
3
4
5
Socket Nut  
Governor Linkage Rod  
Lock Nut  
1/16 in  
(1.6 mm)  
8
Socket  
Governor Arm  
6
Rod length should be 3-1/4 in (83  
mm) between lock nuts. To adjust,  
remove socket from arm and loos-  
en lock nut. Turn socket to adjust  
length. Tighten nut and reattach  
socket to arm.  
. If linkage binds, loosen socket  
nuts and turn sockets until link-  
age works smoothly. Tighten  
nuts.  
6
7
8
Carburetor  
1
Throttle Stop Plate  
Throttle Stop  
4
3-1/4 in  
(83 mm)  
Clearance between plate and stop  
should be 1/16 in (1.6 mm). To ad-  
just clearance, proceed as follows:  
3
2
9
Linkage Pivot Arm  
5
10 Linkage Socket  
11 Lock Nut  
Remove socket at arm and loosen  
lock nut. Turn socket to adjust  
clearance. Reattach socket and  
tighten nut.  
13  
Start engine and run until warm.  
Turn Engine Control switch to Run  
position.  
12  
12 Governor Speed Screw  
13 Lock Nut  
Loosen nut. Turn screw until engine  
runs at weld/power speed.  
Y
Stop engine.  
Close door.  
Tools Needed:  
3/8, 7/16 in  
802 731 / 802 780 / Ref. 801 179 / Ref. 800 161  
OM-4405 Page 37  
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8-6. Adjusting Engine Idle Speed  
Y
Stop engine and let cool.  
Engine idle speed is factory set and  
normally should not require adjust-  
ment. After tuning engine, check  
engine speed with tachometer or  
frequency meter. See table for  
proper no load speed. If necessary,  
adjust idle 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.  
2
5
1
2
3
4
Solenoid Bracket Screws  
Throttle Arm  
Idle Speed Screw  
Throttle Stop  
Loosen bracket screws and move  
arm so screw touches stop. Do not  
release arm. Turn idle speed screw  
to obtain 550 rpm.  
5
Idle Mixture Screw  
Turn mixture screw counterclock-  
wise until engine falters, then turn  
screw clockwise until engine runs  
smoothly.  
1
Turn idle speed screw to obtain  
1250 rpm.  
6
6
7
Solenoid  
Plunger  
7
3
Slide solenoid inside bracket so  
plungerbottoms in solenoid. If nec-  
essary, shim solenoid/bracket to  
prevent linkage from binding. Do  
not readjust idle speed screw when  
adjustingsolenoid.  
Tighten bracket screws. Release  
throttle arm. Recheck idle speed  
and readjust if necessary.  
4
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Stop engine.  
Close door.  
Tools Needed:  
1/4 in  
802 731 / Ref. 115 155-A  
OM-4405 Page 38  
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8-7. Adjusting Governor Sensitivity  
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quire readjustment if weld  
speed is adjusted. Weld speed  
must be readjusted if sensitivity  
is adjusted.  
Be sure carburetor and link-  
ages are adjusted properly be-  
fore adjusting sensitivity.  
3
Start engine. Apply and remove  
load.  
1
2
3
Locking Nuts  
2
1
Sensitivity Adjustment Screw  
Governor Spring  
If engine is slow to pick up load or  
rpm drops under load, adjust spring  
tension as follows:  
Loosen top nut and tighten bottom  
nut to move screw down. Tighten  
nuts.  
If engine hunts with or without load,  
adjust spring tension as follows:  
Loosen bottom nut and tighten top  
nut to move screw up. Tighten nuts.  
Y
Stop engine.  
Close door.  
Tools Needed:  
1/2 in  
802 780 / Ref. 115 155-A  
Notes  
OM-4405 Page 39  
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8-8. Servicing Fuel And Lubrication Systems  
1
3
2
6
5
4
Tools Needed:  
802 731 / Ref. 801 434  
Y
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Stop engine and let cool.  
maintenance label for oil/filter change in-  
formation.  
to open sludge drain valve. Close valve  
when sludge has drained. Remove hose.  
After servicing, start engine and  
check for fuel leaks. Stop engine,  
tighten connections as necessary,  
and wipe up spilled fuel.  
To drain sludge from fuel tank:  
Close door.  
Y
Beware of fire. Do not smoke and  
keep sparks and flames away from  
drained fuel. Dispose of drained fuel  
in an environmentally-safe manner.  
Do not leave unit unattended while  
draining fuel tank.  
To replace fuel filter:  
5
6
Fuel Line  
Fuel Filter  
1
2
3
4
Oil Filter  
Oil Drain Valve And Hose  
Oil Fill Cap/Dipstick  
Fuel Tank Sludge Drain Valve  
Remove clamps and filter. Install new filter  
and clamps. Inspect fuel lines and replace  
if cracked or worn. Wipe up any spilled fuel.  
Y
Properly lift unit and secure in a level  
position. Use adequate blocks or  
stands to support unit while drain-  
ing fuel tank.  
Start engine and check for leaks.  
To change oil and filter:  
Y
Stop engine, tighten connections as  
necessary, and wipe up spilled fuel.  
Route oil drain valve and hose through hole  
in base. See engine manual and engine  
Attach 1/2 ID hose to drain valve. Put metal  
containerunder drain, and use screwdriver  
Close door.  
OM-4405 Page 40  
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8-9. Overload Protection  
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Stop engine.  
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opens, it usually indicates a  
more serious problem exists.  
Contact Factory Authorized  
Service Agent.  
1
2
Fuse F1  
Fuse F2  
F1 and F2 protect the stator exciter  
winding from overload. If F1 opens,  
weld and auxiliary power is low or  
stops entirely. If F2 opens, weld out-  
put is low or stops entirely. 4 kVA/  
kW auxiliary power is still available.  
2
1
3
4
5
Circuit Breaker CB4 (Not  
Shown)  
Circuit Breaker CB5  
(CC/CV Models Only)  
Circuit Breaker CB10 (Not  
Shown)  
6
7
8
Circuit Breaker CB11  
Circuit Breaker CB12  
Circuit Breaker CB13  
8
7
6
CB4 protects the welding arc drive  
(dig) circuit. If CB4 opens, electro-  
de may stick to the workpiece more  
frequently during low voltage (short  
arc length) conditions. CB4 auto-  
matically 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  
output to RC14 stops. On units with  
optionalauxiliary power plant, aux-  
iliary power output at receptacle  
RC5 also stops if CB5 opens.  
4
CB10 protects the engine battery  
circuit. If CB10 opens, the engine  
will not crank. CB10 automatically  
resets when the fault is corrected.  
CB11 protects the engine wiring  
harness. 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 Sec-  
tion 5-2). If CB11 opens on CV mod-  
els, weld output stops (auxiliary  
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 auxiliary power output may not  
be available.  
CB13 protects the engine shut-  
down circuit. If CB13 opens, the en-  
gine cranks but does not start.  
Press button to reset breaker.  
802 729 / Ref. 802 789  
OM-4405 Page 41  
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8-10. 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, Fuel, And Temperature Lights Off.  
Turn Engine Control Switch To Run/Idle  
Position While Pressing Magnetic Shut-  
down 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.  
If Fuel Light Is On, Check Fuel Level.  
If Fault Continues, 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 Ser-  
vice Agent.  
Ref. 201 841  
OM-4405 Page 42  
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8-11. Troubleshooting  
A. Welding – CC Models  
Trouble  
Remedy  
No weld output; auxiliary power output Check position of Ampere Range switch.  
okay.  
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 4-10 and 5-1).  
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 4-10).  
Check fuse F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check inte-  
grated rectifier SR2 and the rotor.  
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.  
No weld output or auxiliary power output. Disconnect equipment from auxiliary power receptacles during start-up.  
Check fuses F1 and F2, and replace if open (see Section 8-9). 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 8-9).  
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.  
Check and tighten connections inside and outside unit.  
Be sure connection to work piece is clean and tight.  
Erratic weld output.  
Use dry, properly stored electrodes.  
Remove excessive coils from weld cables.  
High weld output.  
Low weld output.  
Check engine speed, and adjust if necessary.  
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 8-9). 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 8-9).  
frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.  
length) conditions.  
Low open-circuit voltage.  
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 4-10).  
Reset circuit breaker CB11 (see Section 8-9). Have Factory Authorized Service Agent check control relay  
CR7.  
Repair or replace remote control device.  
Have Factory Authorized Service Agent check OCV control circuit.  
OM-4405 Page 43  
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B. Welding – CC/CV Models  
Trouble  
Remedy  
No weld output; auxiliary power output Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and  
okay.  
connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 4-11 and 6-1).  
Check position of Ampere Range switch.  
Check position of optional polarity switch.  
Reset circuit breaker CB11 (see Section 8-9).  
Reset circuit breaker CB5 (see Section 8-9). Check for faulty remote device connected to RC14.  
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).  
Have Factory Authorized Service Agent check connector board PC6 and connections.  
Check fuse F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check  
brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor.  
No weld output or auxiliary power output. Disconnect equipment from auxiliary power receptacles during start-up.  
Check fuses F1 and F2, and replace if open (see Section 8-9). Have Factory Authorized Service Agent  
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.  
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.  
High weld output.  
Be sure connection to work piece is clean and tight.  
Use dry, properly stored electrodes.  
Remove excessive coils from weld cables.  
Check position of Ampere Range switch and Voltage/Amperage Adjust control.  
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 8-9). 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 8-9).  
frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.  
length) conditions.  
Low open-circuit voltage.  
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 4-11).  
Repair or replace remote control device.  
Constant speed wire feeder does not Reset circuit breaker CB5 (see Section 8-9).  
work.  
Check and secure connections to Remote 14 receptacle RC14 (see Section 4-11).  
Check voltage requirements of wire feeder. 115 volt output not available through Remote 14 recep-  
tacle (see Section 4-11).  
Repair or replace wire feeder.  
Low CV weld output.  
Set Ampere Range switch to highest range.  
Min or max CV weld output only.  
Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.  
Repair or replace remote control device.  
Have Factory Authorized Service Agent check field current regulator board PC1.  
OM-4405 Page 44  
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C. Standard Auxiliary Power  
Trouble  
Remedy  
No auxiliary power output; weld output Reset receptacle circuit breakers.  
okay.  
No auxiliary power or weld output.  
Disconnect equipment from auxiliary power receptacles during start-up.  
Check fuses F1 and F2, and replace if open (see Section 8-9). 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 8-9).  
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.  
High output at auxiliary power Check engine speed, and adjust if necessary.  
receptacles.  
Have Factory Authorized Service Agent adjust auxiliary power field current resistor R3.  
Low output at auxiliary power Check engine speed, and adjust if necessary.  
receptacles.  
Check fuse F1, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check inte-  
grated rectifier SR1, resistor R3, and capacitor C9.  
D. Optional Auxiliary Power Plant  
Trouble  
Remedy  
No or low output at optional auxiliary  
power plant/receptacle RC5  
(CC/CV models only).  
Place Process/Contactor switch in Electrode Hot - Stick position (see Section 6-3).  
Reset circuit breaker CB7 (see Section 7-2).  
Reset circuit breaker CB5 (see Section 8-9).  
Check engine weld/power speed, and adjust if necessary (see Section 8-5).  
Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board  
PC1.  
High output at optional auxiliary power Check engine weld/power speed, and adjust if necessary (see Section 8-5).  
plant/receptacle RC5 (CC/CV models  
only).  
Have Factory Authorized Service Agent check field current regulator board PC1.  
Erratic output at optional auxiliary power Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board  
plant/receptacle RC5 (CC/CV models PC1.  
only).  
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 8-9).  
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.  
OM-4405 Page 45  
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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 8-9). Have Factory Authorized Service Agent check engine-  
wiring harness and components.  
Check battery and replace if necessary. Check engine charging system according to engine manual.  
Have Factory Authorized Service Agent check control relay CR2, and fuel solenoid FS1.  
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 cool-  
ant temperature is too high (see Sections 4-7 and 8-10).  
Engine hard to start in cold weather.  
Use starting Aid (Engine Choke control, see Section 5-1 ).  
Keep battery in good condition. Store battery in warm area off cold surface.  
Use correct grade oil for cold weather (see Section 8-1).  
Engine suddenly stops.  
Check fuel, oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low,  
or coolant temperature is too high (see Sections 4-7 and 8-10).  
See engine manual.  
Check fuel level.  
Engine slowly stopped and cannot be  
restarted.  
Check engine air and fuel filters (see Section 8-8).  
Check engine wiring harness connections.  
See engine manual.  
Battery discharges between uses.  
Turn Engine Control switch off when unit is not running.  
Clean top of battery with baking soda and water solution; rinse with clear water.  
Recharge or replace battery if necessary.  
Periodically recharge battery (approximately every 3 months).  
Engine idles, but does not come up to  
weld speed.  
Have Factory Authorized Service Agent check idle module PC7, current transformer CT1, and throttle  
solenoid TS1.  
Check for obstructed throttle solenoid and linkage.  
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 and linkage.  
Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.  
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Notes  
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SECTION 9 – ELECTRICAL DIAGRAMS  
Figure 9-1. Circuit Diagram For CC Welding Generator  
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201 991-A  
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Figure 9-2. Circuit Diagram For CC/CV Welding Generator  
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201 992-A  
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SECTION 10 – AUXILIARY POWER GUIDELINES  
10-1. Selecting Equipment  
1
2
3
Auxiliary Power Receptacles  
– Neutral Bonded To Frame  
3-Prong Plug From Case  
Grounded Equipment  
2-Prong Plug From Double  
Insulated Equipment  
1
2
3
Be sure equipment  
has this symbol  
and/or wording.  
OR  
aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577  
10-2. Grounding Generator To Truck Or Trailer Frame  
1
2
3
Generator Base  
Metal Vehicle Frame  
Equipment Grounding  
Terminal  
4
Grounding Cable  
Use #10 AWG or larger insulated  
copper wire.  
Y
If unit does not have GFCI re-  
ceptacles, use GFCI-pro-  
tected extension cord.  
3
4
1
GND/PE  
2
OR  
Electrically bond generator  
frame to vehicle frame by  
metal-to-metalcontact.  
2
S-0854  
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10-3. Grounding When Supplying Building Systems  
1
2
EquipmentGrounding  
Terminal  
1
2
Grounding Cable  
GND/PE  
Use #10 AWG or larger insulated  
copper wire.  
3
Ground Device  
Y
Ground generator to system  
earth ground if supplying  
power to a premises (home,  
shop, farm) wiring system.  
Use ground device as stated  
in electrical codes.  
2
3
ST-800 576-B  
10-4. How Much Power Does Equipment Require?  
1
Resistive Load  
3
A light bulb is a resistive load and  
requires a constant amount of pow-  
er.  
VOLTS 115  
AMPS 4.5  
Hz 60  
2
1
2
Non-Resistive Load  
Equipmentwith a motor is a non-re-  
sistive load and requires approxi-  
mately six times more power while  
starting the motor than when run-  
ning (see Section 10-8).  
3
3
Rating Data  
Rating shows volts and amperes,  
or watts required to run equipment.  
AMPERES x VOLTS = WATTS  
EXAMPLE 1: If a drill uses 4.5 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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10-5. 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  
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  
Fan Duty  
550  
650  
800  
1100  
10-6. Approximate Power Requirements For Farm/Home Equipment  
Farm/HomeEquipment  
Rating  
Starting Watts  
Running Watts  
Stock Tank De-Icer  
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  
OM-4405 Page 54  
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10-7. 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  
600  
Circular Saw  
Table Saw  
6-1/2 in  
7-1/4 in  
8-1/4 in  
9 in  
500  
500  
900  
900  
1400  
4500  
6300  
2500  
1720  
3900  
5200  
3000  
6000  
8200  
10500  
1100  
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  
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  
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  
1300  
OM-4405 Page 55  
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10-8. Power Required To Start Motor  
1
2
3
4
Motor Start Code  
Running Amperage  
Motor HP  
4
AC MOTOR  
VOLTS 230 AMPS 2.5  
Hz 60  
PHASE 1  
2
1
3
CODE  
HP  
M
Motor Voltage  
1/4  
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  
G
H
J
K
L
M
N
P
KVA/HP  
6.3  
7.1  
8.0  
9.0  
10.0  
11.2  
12.5  
14.0  
kVA/HP x HP x 1000  
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  
10-9. How Much Power Can Generator Supply?  
1
Limit Load To 90% Of  
Generator Output  
Always start non-resistive (motor)  
loads in order from largest to small-  
est, and add resistive loads last.  
2
5 Second Rule  
1
If motor does not start within 5  
seconds, turn off power to prevent  
motor damage. Motor requires  
more power than generator can  
supply.  
2
Ref. ST-800 396-A / S-0625  
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10-10. Typical Connections To Supply Standby Power  
1
2
3
Power Company Service  
Meter  
Main and Branch Overcurrent  
Protection  
Double-Pole, Double-Throw  
Transfer Switch  
Obtain and install correct switch.  
Switch rating must be same as or  
greater than the branch overcurrent  
protection.  
. Customer-supplied equipment is required if  
generator is to supply standby power during  
emergenciesor power outages.  
4
Circuit Breakers or Fused  
Disconnect Switch  
1
240 V  
Obtain and install correct switch.  
Extension Cord  
Select as shown in Section 10-11.  
Generator Connections  
5
120/240 Volt  
120 V  
60 Hz  
Three-Wire  
Service  
6
120 V  
Connect terminals or plug of ade-  
quate amperage capacity to cord.  
Follow all applicable codes and  
safety practices.  
2
3
Turn off or unplug all equipment  
connected to generator before  
starting or stopping engine. When  
starting or stopping, the engine has  
low speed which causes low volt-  
age and frequency.  
240 V  
120 V  
Load  
120 V  
7
Load Connections  
4
7
CB  
or  
Item 4 is not necessary if circuit  
protection is already present in  
welding generator auxiliary  
power output circuit.  
F1  
6
5
240 V  
120/240 Volt  
Single-Phase  
Three-Wire  
120 V  
120 V  
Generator Output  
Connection  
Ground  
S-0405-A  
OM-4405 Page 57  
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10-11. Selecting Extension Cord (Use Shortest Cord Possible)  
Cord Lengths for 120 Volt Loads  
Y
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)  
4
6
8
10  
12  
14  
5
600  
350 (106)  
250 (76)  
175 (53)  
112 (34)  
87 (26)  
62 (19)  
50 (15)  
50 (15)  
37 (11)  
225 (68)  
150 (46)  
112 (34)  
75 (23)  
50 (15)  
37 (11)  
37 (11)  
137 (42)  
100 (30)  
62 (19)  
37 (11)  
30 (9)  
100 (30)  
62 (19)  
50 (15)  
30 (9)  
7
840  
400 (122)  
275 (84)  
175 (53)  
137 (42)  
112 (34)  
87 (26)  
10  
15  
20  
25  
30  
35  
40  
45  
50  
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)  
62 (19)  
50 (15)  
*Conductor size is based on maximum 2% voltage drop  
Cord Lengths for 240 Volt Loads  
Y
If unit does not have GFCI receptacles, use GFCI-protected extension cord.  
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*  
Current  
(Amperes)  
Load (Watts)  
4
6
8
10  
12  
14  
5
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)  
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)  
7
800 (244)  
550 (168)  
350 (107)  
275 (84)  
225 (69)  
175 (53)  
150 (46)  
125 (38)  
125 (38)  
100 (31)  
10  
15  
20  
25  
30  
35  
40  
45  
50  
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  
OM-4405 Page 58  
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Notes  
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SECTION 11 – PARTS LIST  
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.  
15  
16  
17  
18  
3
2
14  
13  
1
19  
20  
12  
21  
4
11  
22  
5 6  
9
10  
8
7
107  
106  
12  
24  
100 (Fig. 11–7)  
23  
93  
101  
99  
25  
46  
105  
98 (FIG. 11–2 OR 11–3)  
92  
97  
94  
96 (CC ONLY)  
103  
102  
95  
104 (FIG. 11–4 OR 11–5)  
Figure 11-1. Main Assembly  
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32  
58  
59  
57  
55  
31  
33  
56  
28  
30  
29  
27  
54  
61  
52  
51  
26  
34  
60  
53  
62  
108  
50  
35  
63  
64  
48  
47  
84  
77  
78  
79  
69  
65  
66  
68  
80  
81  
82  
67  
49  
83  
91 (SEE FIG. 11–6)  
70  
71  
85  
86  
75  
90  
89  
87  
72  
88  
40  
39  
38  
41  
36  
37  
42  
76  
43  
74  
73  
44  
45  
46  
802 789  
OM-4405 Page 61  
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Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Figure 11-1. Main Assembly  
Quantity  
. . . 1 . . . . . . . . . . . . . 189 824 . . PANEL, gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . . . . 191 623 . . LABEL, warning all panels must be in place while running . . . . . . . . . . . . . 2  
. . . 3 . . . . . . . . . . . . +189 828 . . PANEL, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 4 . . . . . Z1 . . . CC202 151 . . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
C
. . . 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 . . . . . . . . . . . . . 201 701 . . 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  
. . . 12 . . . . . . . . . . . . . 173 352 . . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 3ft  
. . . 13 . . . . . . . . . . . . . 189 708 . . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . . . . . . . . . . 191 307 . . COVER, plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . . . . . . . . . 200 968 . . HOSE, elbow air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 16 . . . . . . . . . . . . . 010 863 . . CLAMP, hose 1.125 – 3.000 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 17 . . . . . . . . . . . . . 189 763 . . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . 189 764 . . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . *192 938 . . FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . *♦192 939 . . FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 19 . . . . . . . . . . . . . 198 457 . . TUBE, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 20 . . . . . . . . . . . . . 200 969 . . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 21 . . . . . . . . . . . . . 189 464 . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 173 909 . . HOSE, sae .312 id x .560 od x 24.000 (order by ft) . . . . . . . . . . . . . . . . . . 2  
. . . 22 . . . . . . . . . . . . . 201 658 . . UPRIGHT, center assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 23 . . . . . . . . . . . . +200 999 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 24 . . . . . . . . . . . . . 196 220 . . BRACKET, hold down fuel tank rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 25 . . . . . . . . . . . . . 192 362 . . BRACKET, mtg nyl 1/2 conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 26 . . . . . . . . . . . . +200 995 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 27 . . . . . . . . . . . . . 189 052 . . GROMMET, plastic neck filler fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 28 . . . . . . . . . . . . . 190 198 . . . . CAP, tank screw-on 3.500 in w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 29 . . . . . . . . . . . . . 192 042 . . LABEL, use gasoline fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 30 . . . . . . . . . . . . . 108 487 . . LABEL, warning falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 31 . . . . . . . . . . . . . 010 875 . . CLAMP, muffler 2.000 dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 32 . . . . . . . . . . . . . 105 740 . . PIPE, muffler exhaust engine 1.925 inlet/outlet . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 33 . . . . . . . . . . . . . 201 851 . . COVER, radiator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 34 . . . . . . . . . . . . . 176 230 . . LABEL, warning hot exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 35 . . . . . . . . . . . . . 191 354 . . SUPPORT, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 36 . . . . . . . . . . . . . 189 245 . . TANK, fuel 23gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 37 . . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . . . . . . . . . . . . . . . . . 084 173 . . . . CLAMP, hose .460 – .545clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 38 . . . . . . . . . . . . . 189 912 . . . . FITTING, stl barbed elbow w/.047 in orf zinc pld . . . . . . . . . . . . . . . . . . . 1  
. . . 39 . . . . . . . . . . . . . 189 909 . . . . FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc . . . . . . . . . . . . . . . 1  
. . . 40 . . . . . . . . . . . . . 201 025 . . . . CAP, fuel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 41 . . . . . . . . . . . . . 189 913 . . . . FITTING, stl barbed elbow zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 42 . . . . . . . . . . . . . 190 142 . . . . SENDER, fuel gauge 9.7500 deep tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 43 . . . . . . . . . . . . . 189 910 . . . . FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc . . . . . . . . . . . . . 1  
. . . 44 . . . . . . . . . . . . . 189 908 . . . . VALVE, drain fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 45 . . . . . . . . . . . . . 181 572 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 46 . . . . . . . . . . . . . 191 446 . . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . . . 6ft  
. . . 47 . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 48 . . . . . . . . . . . . . 200 984 . . ENGINE, Wis-Con gasoline TM-20 (consisting of) . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . *025 474 . . . . SWITCH, thermo temp 240 make 230 open . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . *025 473 . . . . SWITCH, pressure oil 8 psi brake or make . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 201 141 . . . . FTG, adapter oil drain 1/2-20 male x 3/8 npt female . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . *201 142 . . . . BELT, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
OM-4405 Page 62  
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Item  
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Mkgs.  
Part  
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Quantity  
Figure 11-1. Main Assembly (Continued)  
. . . . . . . . . . . . . . . . . . . 172 725 . . BOOT, starter eyelet terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . *114 559 . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 49 . . . . . . . . . . . . . *066 113 . . FILTER, inline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 50 . . . . . . . . . . . . . 200 966 . . HOSE, radiator upper Wis-Con TM-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 51 . . . . . . . . . . . . +202 052 . . GUARD, fan (left side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 52 . . . . . . . . . . . . . 147 923 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 53 . . . . . . . . . . . . . 201 982 . . RADIATOR, w/shroud and 7lb cap 3 row core . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 605 982 . . . . CAP, radiator pressure 7 lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 54 . . . . . . . . . . . . . 201 749 . . UPRIGHT, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 55 . . . . . . . . . . . . . 190 206 . . CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng . . . . . . . . . . . . . 1  
. . . 56 . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 57 . . . . . . . . . . . . . 190 207 . . CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng . . . . . . . . . . . . . 1  
. . . 58 . . . . . . . . . . . . . 203 430 . . BRACKET, battery holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 59 . . . . . . . . . . . . . 190 897 . . BATTERY, stor 12V 650crk 110rsv gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 60 . . . . . . . . . . . . . 201 006 . . BOLT, j stl .312–18 x 8.500 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 61 . . . . . . . . . . . . +201 183 . . COVER, battery access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 62 . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 63 . . . . . . . . . . . . . 201 996 . . LABEL, warning do not operate with guard missing . . . . . . . . . . . . . . . . . . 2  
. . . 64 . . . . . . . . . . . . . 200 967 . . HOSE, radiator lower Wis-Con TM-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 65 . . . . . . . . . . . . +200 990 . . GUARD, fan (right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 66 . . . . . . . . . . . . . 190 992 . . KEEPER, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 67 . . . . . . . . . . . . . 190 076 . . CHANNEL, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 68 . . . . . . . . . . . . . 199 592 . . LATCH, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 69 . . . . . . . . . . . . . 201 031 . . LABEL, gasoline engine maintenance Wis-Con TM-20 . . . . . . . . . . . . . . . 1  
. . . 70 . . . . . . . . . . . . +200 989 . . DOOR, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 71 . . . . . . . . . . . . . 189 975 . . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 72 . . . . . . . . . . . . . 190 190 . . TANK, coolant recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 73 . . . . . . . . . . . . . 201 591 . . STOP, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 74 . . . . . . . . . . . . . 189 826 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 75 . . . . . . . . . . . . . 191 626 . . BUMPER, door engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 76 . . . . . . . . . . . . . 189 827 . . PANEL, gen RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 77 . . . . . . . . . . . . . 199 849 . . SCREW, 625-11 x 4.00hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 78 . . . . . . . . . . . . . 071 731 . . WASHER, flat .656 ID x 2.250 OD x .187T stl pld . . . . . . . . . . . . . . . . . . . . 4  
. . . 79 . . . . . . . . . . . . . 200 985 . . BRACKET, mtg engine Wis-Con TM-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 80 . . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 81 . . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 82 . . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 . . . . . . . . . . . . . . . . . . 4  
. . . 83 . . . . . . . . . . . . . 135 205 . . NUT, 625-11 .94hex .76H stl pld elastic stop nut . . . . . . . . . . . . . . . . . . . . . 4  
. . . 84 . . . . . . . . . . . . . . 190757 . . SOLENOID ASSY (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 113658 . . . . LINKAGE, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 115857 . . . . BRACKET, mtg solenoid idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 005373 . . . . SOLENOID, 14vdc .84 amp pull type cont . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 010837 . . . . PIN, spring cs .093 x .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 199 505 . . HOSE, oil drain assy 32 in (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 85 . . . . . . . . . . . . . 165 271 . . . . VALVE, oil drain 3/8-18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 86 . . . . . . . . . . . . . 176 529 . . . . FITTING, hose brs barbed fem 1/2tbg x 3/8NPT . . . . . . . . . . . . . . . . . . . 1  
. . . 87 . . . . . . . . . . . . . . 113 854 . . . . HOSE, SAE .500 ID x .780 OD xc oil (order by ft) . . . . . . . . . . . . . . . . . . 3ft  
. . . 88 . . . . . . . . . . . . . 197 448 . . FITTING, hose brs barbed elbow m 1/2 tbg x 3/8 npt . . . . . . . . . . . . . . . . . 1  
. . . 89 . . . . . . . . . . . . . 201 141 . . FITTING, engine adapter oil drain 12-20 x 3/8 npt female . . . . . . . . . . . . . 1  
. . . 90 . . . . . . . . . . . . . 201 362 . . WASHER, oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 91 . . . . . . . . . . . Figure 11-6 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 92 . . . . . . . . . . . . . 191 897 . . BRACKET, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 93 . . . . . . . . . . . . . 191 512 . . BRACKET, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 94 . . . . . . . . . . . . . 190 250 . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 95 . . . . . . . . . . . . . 190 179 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 96 . . . . . R2 . . . CC189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 97 . . . . . R3 . . . . 189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 98 . . . . . . Figure 11-2, Figure 11-3 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
OM-4405 Page 63  
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Item  
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Dia.  
Mkgs.  
Part  
No.  
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Quantity  
Figure 11-1. Main Assembly (Continued)  
. . . 99 . . . . . . . . . . . . . 189 731 . . FIREWALL, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 100 . . . . . . . . . . Figure 11-7 . . MAIN RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 101 . . . . . . . . . . . . 191 448 . . TOP, cover front upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 102 . . . . . . . . . . . +201 750 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 103 . . . . . . . . . . . . 182 761 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 104 . . . . . Figure 11-4, Figure 11-5 PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 105 . . . . . . . . . . . . . 202130 . . XFMR, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
C
. . 106 . . . . . . . . . . . V193 453 . . BRACKET, mtg box fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
C
. . 107 . . . PC1 . . V189 143 . . MODULE, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 108 . . . . . . . . . . . +147 923 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 190 058 . . NUT, .250-20 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
. . . . . . . . . . . . . . . . . . . 049 525 . . NUT, 312-18 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
. . . . . . . . . . . . . . . . . . . 202 022 . . KIT, label (includes safety and informational labels) . . . . . . . . . . . . . . . . . . 1  
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order  
label individually or as part of Label Kit 202 022.  
*Recommended Spare Parts.  
C
CC models only.  
CC/CV models only.  
C
C
V
♦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.  
4
14  
18  
6
3
17  
8
7
10  
20  
2
1
9
15  
11  
16  
13  
12  
19  
5
802 551-A  
Figure 11-2. Control Box Assembly – CC Models  
OM-4405 Page 64  
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Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 11-2. Control Box Assembly – CC Models (Figure 11-1 Item 98)  
. . . 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  
. . . . . . . . . . . . . . . . . . . 201 681 . . 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 Figure 11-4) . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . S6 . . . . . 011 622 . . . . SWITCH, tgl 3pdt 15a 125vac on–none–on spd term  
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 11-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 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  
. . . . . . . . . . . . . . . . . . . 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 . . . . 195706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 16 . . . . CR4 . . . . 113247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . CR6 . . . . 090104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1  
. . . 18 CR1, CR2, CR3 090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 3  
. . . . . . . . . . . . . . . . . . . 201 357 . . HARNESS, engine control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 19 . . . D8/C8 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 20 . . . . CB10 . . . 190 374 . . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . . 1  
*Recommended Spare Parts.  
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-4405 Page 65  
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4
16  
3
15  
17  
11  
18  
10  
2
1
13  
14  
7
6
12  
8
9
5
802 360  
Figure 11-3. Control Box Assembly – CC/CV Models  
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 11-3. Control Box Assembly – CC/CV Models (Figure 11-1 Item 98)  
. . . 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  
. . . . . . . . . . . . . . . . . . . 201 495 . . HARNESS, control box, cv weld control (consisting of) . . . . . . . . . . . . . . . 1  
. . . 10 . . . . SR1 . . . 035 704 . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 11 . . . . CR5 . . . 090 104 . . . . RELAY, encl 12VDC SPST 30A/15VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . RC4 . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . . . . . 1  
. . . . . . . . . . RC3 . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . . . . . 1  
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . . 1  
. . . 12 CB11, 12, 13 139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . . 3  
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . S6 . . . . 193 324 . . . . SWITCH, rotary 6 position gold contacts  
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 11-5) . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH,tgl spdt 15a 125vac on–none–on spd term chr  
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 11-5) . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 150 316 . . . . CONN, rect univ 039 6p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . . . 6  
OM-4405 Page 66  
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Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 11-3. Control Box Assembly – CC/CV Models (Continued)  
. . . . . . . . . . . . . . . . . . . 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 . . . . 195706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . CR4 . . . . 113247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . CR6 . . . . 090104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1  
. . . 16 CR1, CR2, CR3 090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 3  
. . . . . . . . . . . . . . . . . . . 201 357 . . HARNESS, engine control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 17 . . . D8/C8 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . CB10 . . . 190 374 . . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
. . . . . . . . . . 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  
*Recommended Spare Parts.  
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-4405 Page 67  
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4
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.  
3
5
2
1
6
7
8
9
10  
40  
39  
38  
11  
12  
13  
14  
15  
35  
36  
34  
16  
17  
32  
33  
31  
37  
30  
29  
28  
18  
19  
21  
20  
22  
27  
26  
23  
802 799  
25  
24  
Figure 11-4. Panel, Front w/Components – CC Models  
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 11-4. Panel, Front w/Components – CC Models (Figure 11-1 Item 104)  
. . . 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  
. . . . . . . . . . . . . . . . . . . 202 223 . . BUS BAR, idealized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
OM-4405 Page 68  
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Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 11-4. Panel, Front w/Components – CC Models (Continued)  
. . . 5 . . . . . R1 . . . . 188 635 . . RHEOSTAT, WW 300W 34 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 6 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
. . . 7 . . . . . S6 . . . . . 011 622 . . SWITCH, tgl DPDT 15A 125VAC (included in control box harness,  
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Figure 11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in  
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see Figure 11-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . RC13 . . . 032 897 . . RECEPTACLE, twlk grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . . . S1 . . . . 176 606 . . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 11 . . . . MS1 . . . 189 698 . . SWITCH, magnetic manual reset low current . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 12 . . . . CB1 . . . 201 083 . . CIRCUIT BREAKER, man reset 2P 20 A, 250VAC . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 201 109 . . HARNESS, auxiliary power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 13 . . . . CB2 . . . 093 996 . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . 3  
. . . 14 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . 1  
. . . 15 . . . . RC1 . . . 147 632 . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . . 1  
. . . 16 . . . . . . . . . . . . . 190 861 . . LABEL, warning electric shock and moving parts . . . . . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . . . . . . . . . +201 106 . . PANEL, aux pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . 083 030 . . STUD, brs .250–20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 19 . . . . . . . . . . . . . 601 836 . . NUT, 250–20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
. . . 20 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 21 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 22 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 23 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 24 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 25 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 26 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 27 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 28 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 29 . . . . . . . . . . . . . 193 260 . . COVER, receptacle 2.250 dia lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 30 . . . . . . . . . . . . . 193 258 . . COVER, receptacle GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 31 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 32 . . . . . . . . . . . . . 193 143 . . BOOT, magnetic shutdown switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 33 . . . . . . . . . . . . . 200 993 . . CONTROL, push-pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 34 . . . . . . . . . . . . . . 119 014 . . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 35 . . . . . PL1 . . . 191 241 . . LED, red 12V 4 ind lights panel mtg round . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 36 . . . . FUEL . . . 192 265 . . GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 37 . . . . . HM . . . . . 118 058 . . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 38 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 39 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 40 . . . . . . . . . . . . . 148 723 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 024 103 . . BLANK, snap–in nyl .750 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order  
label individually or as part of Label Kit 192 505 or Label Kit 202 022.  
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-4405 Page 69  
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Figure 11-5. Panel, Front w/Components – CC/CV Models  
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 11-5. Panel, Front w/Components – CC/CV Models (Figure 11-1 Item 104)  
. . . 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  
. . . . . . . . . . . . . . . . . . ♦202223 . . BUS BAR, idealized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
OM-4405 Page 70  
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Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 11-5. 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 Figure 11-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 7 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in  
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see Figure 11-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . MS1 . . . 189 698 . . SWITCH, magnetic manual reset low current . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 13 . . . . CB1 . . . 201 083 . . CIRCUIT BREAKER, man reset 2P 20 A, 250VAC . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 201 109 . . HARNESS, auxiliary power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . CB2 . . . 093 996 . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . 1  
. . . 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 . . . . RC5 . . ♦182 954 . . RCPT, str 3P4W 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . ♦025 248 . . STAND-OFF, insul .250-20 x 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 19 . . . . . . . . . . . . ♦604 102 . . CONNECTOR, clamp cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 20 . . . . . . . . . . . . ♦197 527 . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 21 . . . . . . . . . . . . ♦197 363 . . TERMINAL, ring tng screw clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
. . . 22 . . . . CB7 . . ♦196 780 . . CIRCUIT BREAKER, man reset 3p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 23 . . . . . . . . . . . . +201 106 . . PANEL, auxiliary power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 23 . . . . . . . . . . . +♦201 107 . . PANEL, auxiliary power (full kVA option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 24 . . . . . . . . . . . . ♦196 781 . . BOOT, circuit breaker 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 25 . . . . . . . . . . . . ♦197 508 . . PLUG, protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 26 . . . . . . . . . . . . ♦077 440 . . BUSHING, conduit 1 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 27 . . . . . . . . . . . . . 601 836 . . NUT, 250–20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
. . . 28 . . . . . . . . . . . . ♦197 291 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 29 . . . . . . . . . . . . . 083 030 . . STUD, brs .250–20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . CT2 . . ♦197 433 . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 30 . . . . . . . . . . . . . 190 861 . . LABEL, warning electric shock and moving parts . . . . . . . . . . . . . . . . . . . . 1  
. . . 30 . . . . . . . . . . . . ♦197 399 . . LABEL, warning 3 ph auxiliary power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 31 . . . . . . . . . . . . . 193 260 . . COVER, receptacle 2.250 dia lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 32 . . . . . . . . . . . . . 193 258 . . COVER, receptacle GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 33 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 34 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 35 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 36 . . PC4, PC5 . 189 744 . . CIRCUIT CARD ASSEMBLY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 37 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 38 . . . . . . . . . . . . . 134 201 . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
. . . 39 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 40 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 41 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 42 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 43 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 44 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 45 . . . . . . . . . . . . . 193 143 . . BOOT, magnetic shutdown switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 46 . . . . . . . . . . . . . 200 993 . . CONTROL, push-pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 47 . . . . . . . . . . . . . . 119 014 . . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 48 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 49 . . . . . . . . . . . . . 170 391 . . CONN, circ ms protective cap size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 50 . . . . . PL1 . . . 191 241 . . LED, red 12V 4 ind lights panel mtg round . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 51 . . . . FUEL . . . 192 265 . . GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 52 . . . . . HM . . . . . 118 058 . . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
OM-4405 Page 71  
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Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 11-5. Panel, Front w/Components – CC/CV Models (Continued)  
. . . 53 . . . . . . . . . . . . . 097 922 . . KNOB, pointer .875 dia x .250 ID w/set screws plstc . . . . . . . . . . . . . . . . . 1  
. . . 54 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 55 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 56 . . . . . . . . . . . . . 097 924 . . KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc . . . . . . . . . . . . . . . . . 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  
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order  
label individually or as part of Label Kit 202 022.  
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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17  
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11  
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23  
18  
19  
13  
12  
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9
20  
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8
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802 800  
Figure 11-6. Generator  
OM-4405 Page 72  
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Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 11-6. Generator (Figure 11-1 Item 91)  
. . . 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/aux 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  
. . . 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 . . . . . . . . . . . . . 201 098 . . ROTOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 12 . . . . . . . . . . . . . 024 617 . . . . RING, rtng ext 1.375 shaft x .050thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 13 . . . . . . . . . . . . . 053 390 . . . . BEARING, ball rdl sgl row 1.370 x 2.830 x .6 . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . . . . . . . . . . 195 547 . . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . . . . . . . . . 049 026 . . SCREW, M10-1.5 x 25hexhd pln 8.8pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
. . . 16 . . . . . . . . . . . . . 083 883 . . WASHER, lock .402 ID x 0.709 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
. . . 17 . . . . . . . . . . . . . 202 301 . . . . PLATE, flex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . 605 231 . . . . SCREW, m10–1.5x 35 hex hd–pln 8.8 pld . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 19 . . . . . . . . . . . . . 194 512 . . . . WASHER, flat 1.250 od x .406id x 7ga thk stl pld . . . . . . . . . . . . . . . . . . . 4  
. . . 20 . . . . . . . . . . . . . 183 387 . . . . WASHER, cone .380idx .860odx.109t stl pld 4000lbs . . . . . . . . . . . . . . 6  
. . . 21 . . . . . . . . . . . . . 198 631 . . . . NUT, m10 hex lock nut stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 22 . . . . . . . . . . . . . 201 139 . . FLYWHEEL, engine Wis-Con TM-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 23 . . . . . . . . . . . . . 201 140 . . ADAPTER, engine Wis-Con TM-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 24 . . . . . . . . . . . . . 191 579 . . COVER, starter hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 200 991 . . GUARD, starter hole Wis-Con TM-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . 191 580 . . COVER, starter hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 25 . . . . . . . . . . . . . 172 555 . . SCREW, M10-1.5 x 50hexhd pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
. . . 26 . . . . . . . . . . . . . 602 159 . . SCREW, .312–18x .75 hexwhd.66d stl pld slffmg tap–rw . . . . . . . . . . . . . 6  
. . . 27 . . . . . . . . . . . . . 601 950 . . SCREW, .312-18 x 2.00 hexhd pln gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 28 . . . . . . . . . . . . . . 602 211 . . WASHER, lock .318 ID x 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
. . . 29 . . . . . . . . . . . . . 139 341 . . WASHER, exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 30 . . . . . . . . . . . . . *190 823 . . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
. . . 31 . . . . . . . . . . . . . 188 560 . . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
. . . 32 . . . . . . . . . . . . . 189 142 . . BRUSHHOLDER ASSEMBLY, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 33 . . . . . . . . . . . . . 602 242 . . WASHER, flat .375IDx0.875odx.083t stl pld . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 34 . . . . . . . . . . . . . 604 534 . . SCREW, .312–18x1.25 hex hd–pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . 190 259 . . HARNESS, brush (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . PLG1 . . . 135 134 . . . . CONNECTOR, 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 202 022.  
*Recommended Spare Parts.  
♦Optional  
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-4405 Page 73  
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4
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802 279-A  
Figure 11-7. Main Rectifier Assembly  
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 11-7. Main Rectifier Assembly (Figure 11-1 Item 100)  
. . . . . . . . . . . . . . . . . . . 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.  
OM-4405 Page 74  
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Effective January 1, 2000  
(Equipment with a serial number preface of “LA” 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.  
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting  
Torches  
Call  
1-800-4-A-MILLER  
for your local  
Miller distributor.  
*
*
*
*
*
Remote Controls  
Accessory Kits  
Replacement Parts (No labor)  
Spoolmate 185 & Spoolmate 250  
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.  
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  
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.  
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.  
1. 5 Years Parts – 3 Years Labor  
*
*
Original main power rectifiers  
Inverters (input and output rectifiers only)  
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.  
2. 3 Years — Parts and Labor  
*
*
*
*
*
*
Transformer/Rectifier Power Sources  
Plasma Arc Cutting Power Sources  
Semi-Automatic and Automatic Wire Feeders  
Inverter Power Supplies  
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.  
Intellitig  
Engine Driven Welding Generators  
(NOTE: Engines are warranted separately by  
the engine manufacturer.)  
3. 1 Year — Parts and Labor  
*
*
DS-2 Wire Feeder  
Motor Driven Guns (w/exception of Spoolmate  
185 & Spoolmate 250)  
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  
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 140  
PROVISION,  
MIGHT  
ARISE  
BY  
IMPLICATION,  
Spot Welders  
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  
Miller Cyclomatic Equipment  
Running Gear/Trailers  
Plasma Cutting Torches (except APT & SAF  
Models)  
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.  
*
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  
Induction Heating Coils and Blankets  
miller_warr 7/00  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 for:  
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  
2001 Miller Electric Mfg. Co. 1/01  
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