OM-492
2007−05
190 603BF
Processes
MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
™
PipePro 304
File: Engine-Driven
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-2. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-5. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-2. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-3. Adding Coolant To Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-4. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-6. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-7. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-8. Remote 14 Receptacle RC14 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-9. Guidelines For Installing Customer-Supplied Emergency Air Shutdown Valve . . . . . . . . . . . . . . . . . . . 22
5-10. Operating Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-1. Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-2. Description Of Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-3. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-4. Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-5. Lift-Arc TIG Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-6. Recommendations For Extreme Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-1. Generator Power Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-2. Optional GFCI Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-3. Wiring Instructions For Optional 240 Volt, 3-Phase Twistlock Plug (NEMA L15-30P) . . . . . . . . . . . . . . 29
7-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) . . . . . . . . . . . . . . . . . . . 30
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TABLE OF CONTENTS
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-3. Servicing Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-5. Servicing Engine Lubrication And Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8-6. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-7. Replacing Throttle Solenoid TS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8-8. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-9. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-10. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
OPTIONS AND ACCESSORIES
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2007−04
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
.
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Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
NOTICE − Indicates statements not related to personal injury.
1-2. Arc Welding Hazards
D
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.
When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequentlyinspect input power cord for damage or bare wiring —
replace cord immediately if damaged — bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
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
follow all Safety Standards.
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Only qualified persons should install, operate, maintain, and
repair this unit.
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During operation, keep everybody, especially children, away.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
ELECTRIC SHOCK can kill.
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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.
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also live when power is
on. In semiautomatic or automatic wire welding, the wire, wire reel,
drive roll housing, and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly grounded equip-
ment is a hazard.
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Do not touch live electrical parts.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
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.
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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.
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Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
SIGNIFICANT DC VOLTAGE exists in inverters after stop-
ping engine.
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Use AC output ONLY if required for the welding process.
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Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
If AC output is required, use remote output control if present on
unit.
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Additionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomaticDC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
HOT PARTS can cause severe burns.
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Do not touch hot parts bare handed.
Allow cooling period before working on equip-
ment.
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To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
FLYING METAL or DIRT can injure eyes.
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Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
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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).
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Wear approved safety glasses with side shields even under your
welding helmet.
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
OM-492 Page 1
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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).
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
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Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
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, sparks, and fire haz-
ards.
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If ventilation is poor, wear an approved air-supplied respirator.
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Do not use welder to thaw frozen pipes.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
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Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
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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.
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.
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 while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
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Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
NOISE can damage hearing.
Noise from some processes or equipment can dam-
age hearing.
BUILDUP OF GAS can injure or kill.
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Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use ap-
proved air-supplied respirator.
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Wear approved ear protection if noise level is
high.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
ARC RAYS can burn eyes and skin.
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Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
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.
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ImplantedMedical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
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Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
CYLINDERS can explode if damaged.
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Shielding gas cylinders contain gas under high pres-
sure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process, be
sure to treat them carefully.
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Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, 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.
WELDING can cause fire or explosion.
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Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
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,
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
and hot equipment can cause fires and burns. Accidental contact of
electrodeto metal objects can cause sparks, explosion, overheating,
or fire. Check and be sure the area is safe before doing any welding.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
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Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
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Turn face away from valve outlet when opening cylinder valve.
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Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
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Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
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Watch for fire, and keep a fire extinguisher nearby.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
OM-492 Page 2
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1-3. Engine Hazards
STEAM AND HOT COOLANT can burn.
BATTERY EXPLOSION can BLIND.
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If possible, check coolant level when engine is
cold to avoid scalding.
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Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
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Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
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Stop engine before disconnecting or connect-
ing battery cables or servicing battery.
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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.
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If the engine is warm, checking is needed, and there is no over-
flow tank, follow the next two statements.
Disconnect negative (−) cable first and connect it last.
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Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before
completely removing cap.
FUEL can cause fire or explosion.
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Stop engine and let it cool off before checking or
adding fuel.
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Do not add fuel while smoking or if unit is near
any sparks or open flames.
Using a generator indoors CAN KILL
YOU IN MINUTES.
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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.
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Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
Always keep nozzle in contact with tank when fueling.
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NEVER use inside a home or garage, EVEN IF
doors and windows are open.
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Only use OUTSIDE and far away from windows, doors, and
vents.
MOVING PARTS can cause injury.
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Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
BATTERY ACID can BURN SKIN and EYES.
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Stop engine before installing or connecting unit.
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Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
Have only qualified people remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
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D
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To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
ENGINE HEAT can cause fire.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
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Do not locate unit on, over, or near combustible
surfaces or flammables.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
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Keep exhaust and exhaust pipes way from
flammables.
Block flywheel so that it will not turn while working on generator
components.
HOT PARTS can cause severe burns.
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Do not touch hot parts bare handed.
Allow cooling period before working on equip-
ment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
EXHAUST SPARKS can cause fire.
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Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
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1-4. Compressed Air Hazards
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
BREATHING COMPRESSED AIR can
cause serious injury or death.
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Release air pressure from tools and system be-
fore servicing, adding or changing attach-
ments, or opening compressor oil drain or oil fill
cap.
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Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
COMPRESSED AIR can cause injury.
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Wear approved safety goggles.
Do not direct air stream toward self or others.
OM-492 Page 3
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HOT METAL from air arc cutting and
gouging can cause fire or explosion.
READ INSTRUCTIONS.
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Read Owner’s Manual before using or servic-
ing unit.
Stop engine and release air pressure before
servicing.
Use only genuine replacement parts from the
manufacturer.
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Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
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Do not touch hot compressor or air system
parts.
Let system cool down before touching or ser-
vicing.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
WELDING WIRE can cause injury.
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Do not install or place unit on, over, or near
combustiblesurfaces.
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Do not press gun trigger until instructed to do
so.
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Do not install unit near flammables.
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Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
OVERUSE can cause OVERHEATING.
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Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
Lift and support unit only with proper equipment
and correct procedures.
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Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
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Do not block or filter airflow to unit.
D
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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.
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Put on grounded wrist strap BEFORE handling
boards or parts.
OVERHEATING can damage motors.
D
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
Turn off or unplug equipment before starting or
stopping engine.
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Do not let low voltage and frequency caused by
low engine speed damage electric motors.
TILTING OF TRAILER can cause injury.
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Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
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Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
FLYING SPARKS can cause injury.
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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.
READ INSTRUCTIONS.
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D
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Read Owner’s Manual before using or servic-
ing unit.
Use only genuine replacement parts from the
manufacturer.
Perform engine and air compressor mainte-
nance and service according to this manual
and the engine/air compressor (if applicable)
manuals.
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Sparks can cause fires — keep flammables away.
MOVING PARTS can cause injury.
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Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
OM-492 Page 4
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H.F. RADIATION can cause interference.
ARC WELDING can cause interference.
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High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
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Electromagnetic energy can interfere with
sensitive electronic equipment such as micro-
processors, computers, and computer-driven
equipmentsuch as robots.
Be sure all equipment in the welding area is
electromagneticallycompatible.
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The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
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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.
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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.
1-6. California Proposition 65 Warnings
For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc-
tive harm.
For Diesel Engines:
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-7. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044,website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036–8002 (phone:
212-642-4900,website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184,website: www.global.ihs.com).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandards Association, Standards Sales, 5060 Mississauga,
1-8. 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, or using a
cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
About Implanted Medical Devices:
ImplantedMedical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-492 Page 5
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_2007−04fre
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
.
I
n
d
i
q
u
e
d
e
s
i
n
s
t
r
u
c
t
i
o
n
s
s
p
é
c
i
f
i
q
u
e
s
.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
2-2. Dangers relatifs au soudage à l’arc
manuelAC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas tra-
vailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à
l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
1910.147(voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformé-
ment à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
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.
En effectuant les raccordements d’entrée fixer d’abord le conduc-
teur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chau-
des.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est
pas endommagé ou dénudé − remplacer le cordon immédiatement
s’il est endommagé − un câble dénudé peut provoquer une électro-
cution.
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
sécurité énumérées à la section 2-7. Veuillez lire et respecter
toutes ces normes de sécurité.
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L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrementles enfants.
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UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquerune électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
D
dès que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce 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
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Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
D
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Ne pas enrouler les câbles autour du corps.
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Ne jamais toucher les pièces électriques sous tension.
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.
Porter des gants et des vêtements de protection secs ne compor-
tant pas de trous.
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Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide dou-
blée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
conformémentà ce manuel.
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 avec tout objet métallique.
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S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact
physique éventuel avec la pièce ou la terre.
Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D
D
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Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.
D
D
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Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
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Des précautions de sécurité supplémentaires sont requises dans
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures mé-
talliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
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Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
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Couper l’alimentation du poste et décharger les condensateurs
d’entrée comme indiqué dans la Section Maintenance avant de
toucher des composants.
OM-492 Page 6
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D
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
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Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
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Ne pas toucher à mains nues les parties chau-
des.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
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Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
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Porter des vêtements confectionnés avec des matières résistan-
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
DES PIECES DE METAL ou DES SA-
LETES peuvent provoquer des bles-
sures dans les yeux.
LE SOUDAGE peut provoquer un in
cendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites peu
provoquer leur éclatement. Des étincelles peuven
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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
métalliquesvolantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies e
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliquespeut provoquer des étincelles, une explosion, un surchauf
fement ou un incendie. Avant de commencer le soudage, vérifier e
s’assurer que l’endroit ne présente pas de danger.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES FUMÉES ET LES GAZ peuvent être
dangereux.
D
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusementavec des protections homologués.
Le soudage génère des fumées et des gaz. Leur
inhalationpeut être dangereux pour votre santé.
D
D
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Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.
D
D
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À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
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Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les nor-
mes de sécurité).
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Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
peurs inflammables (vapeur d’essence, par exemple).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo-
quant des risques d’électrocution, d’étincelles et d’incendie.
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Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for-
mer des gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtementset tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
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D
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Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
lées.
En cas de non utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
LES ACCUMULATIONS DE GAZ ris
quent de provoquer des blessures ou
même la mort.
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D
D
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Avant de souder, retirer toute substance combustible de vos po-
ches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-
ce d’étincelles incandescentes ni de flammes.
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateurd’adduction d’air homologué.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
LES RAYONS DE L’ARC peuvent pro
voquer des brûlures dans les yeux e
sur la peau.
LE BRUIT peut affecter l’ouïe.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Le bruit des processus et des équipements peut affec
l’ouïe.
D
Porter des protections approuvés pour les ore
les si le niveau sonore est trop élevé.
OM-492 Page 7
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D
D
Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
LES CHAMPS MAGNETIQUES peuv-
ent affecter des implants médicaux.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D
Porteur de simulateur cardiaque ou autre im-
plants médicaux, rester à distance.
D
D
Ne jamais placer une torche de soudage sur une bouteille à gaz.
D
Les porteurs d’implants doivent d’abord consulter leur médecin
avant de s’approcher des opérations de soudage à l’arc, de sou-
dage par points, de gougeage, du coupage plasma ou de chauf-
fage par induction.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
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.
Si des BOUTEILLES sont endomma
gées, elles pourront exploser.
D
D
D
D
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
Des bouteilles de gaz protecteur contiennent du ga
sous haute pression. Si une bouteille est endomma
Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisationou de branchement de la bouteille.
gée, elle peut exploser. Du fait que les bouteilles de gaz fon
normalement partie du procédé de soudage, les manipuler ave
précaution.
Utiliser les équipements corrects, les bonnes procédures et suffi-
samment de personnes pour soulever et déplacer les bouteilles.
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers existant en relation avec le moteur
D
Seules des personnes qualifiées sont autorisées à enlever les por-
tes, panneaux, recouvrements ou dispositifs de protection pour
effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.
L’EXPLOSION DE LA BATTERIE peu
RENDRE AVEUGLE.
D
Toujours porter une protection faciale, des gants
en caoutchouc et vêtements de protection lors
d’une intervention sur la batterie.
D
D
D
Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien,débrancher le câble négatif (−) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
D
D
D
Arrêter le moteur avant de débrancher ou de brancher les câbles
de batterie.
Remettreen place les panneaux ou les dispositifs de protection et
fermer les portes à la fin des travaux d’entretien et avant de faire
démarrer le moteur.
Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
D
D
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
mise en route accidentelle du moteur.
Ne pas utiliser le poste de soudage pour charger les batteries ou
des véhicules de démarrage rapide.
Bloquerle volant moteur pour éviter sa rotation lors d’une interven-
tion sur le générateur.
D
D
Observer la polarité correcte (+ et −) sur les batteries.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
D
Ne pas toucher à mains nues les parties chau-
des.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
LE CARBURANT MOTEUR peut provo
quer un incendie ou une explosion.
D
D
Arrêter le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
D
Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
D
Ne pas faire le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
D
D
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.
D
D
Jeter les chiffons dans un récipient ignifuge.
D
Il est préférable de vérifier le liquide de refroi-
dissementune fois le moteur refroidi pour éviter
de se brûler.
Toujours garder le pistolet en contact avec le réservoir lors du
remplissage.
D
Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si pré-
cisé autrement dans la section maintenance du manuel du
moteur).
DES ORGANES MOBILES peuvent pro
voquer des blessures.
D
D
Si le moteur est chaud et que le liquide doit être vérifié, opérer com-
me suivant.
D
Ne pas approcher les mains des ventilateurs,
courroies et autres pièces en mouvement.
Mettre des lunettes de sécurité et des gants, placer un torchon sur
le bouchon du radiateur.
D
Maintenirfermés et fixement en place les portes, panneaux, re-
couvrements et dispositifs de protection.
D
Dévisser le bouchon légèrement et laisser la vapeur s’échapper
avant d’enlever le bouchon.
D
Arrêter le moteur avant d’installer ou brancher l’appareil.
OM-492 Page 8
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L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
LA CHALEUR DU MOTEUR peut pro-
voquer un incendie.
D
Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces inflammables.
D
Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisi-
ble et inodore.
D
Tenir à distance les produits inflammables de l’échappement.
D
JAMAIS utiliser dans une maison ou garage,
même avec les portes et fenêtres ouvertes.
D
Uniquementutiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
L’ACIDE DE LA BATTERIE peut pro-
voquer des brûlures dans les YEUX et
sur la PEAU.
D
Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.
D
D
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
D
Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
D
Rincer immédiatement les yeux et la peau à l’eau.
2-4. Dangers liés à l’air comprimé
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un in-
cendie ou une explosion.
RESPIRER L’AIR COMPRIMÉ peut pro-
voquer des blessures graves ou causer
la mort.
D
Ne pas couper ou gouger à proximité de pro-
duits inflammables.
Surveillez et garder un extincteur à proximité.
D
D
Ne pas utiliser l’air comprimé pour respirer.
Utiliser l’air comprimé seulement pour le cou-
page, gougeage et les outils pneumatiques.
D
DES PIECES CHAUDES peuvent provo-
quer des brûlures et blessures.
L’AIR COMPRIMÉ peut provoquer
des blessures.
D
Ne pas toucher le compresseur ou d’autres
éléments du circuit air comprimé chauds.
D
D
Porter des lunettes de sécurité approuvées.
Ne pas diriger le jet d’air vers d’autres ou
soi-même.
D
Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la
maintenance.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provo-
quer des blessures.
LIRE LES INSTRUCTIONS.
D
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D
Relâcher la pression d’air de l’outillage ou du
système avant d’effectuer la maintenance,
avant de changer ou de rajouter des éléments
ou avant d’ouvrir la purge ou le bouchon de
remplissaged’huile.
D
Arrêter le moteur et relâcher la pression avant
d’effectuer la maintenance.
D
N’utiliser que les pièces de rechange recommandées par le
constructeur.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLO-
SION.
LA CHUTE DE L’APPAREIL peut blesser.
D
Utiliser l’anneau de levage pour lever l’appareil et
les accessoires correctement installées seuls,
PAS les bouteilles de gaz. Ne pas dépasser le
poids nominal maximal de l’œilleton (voir les spé-
cifications).
D
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D
Ne pas installer l’appareil à proximité de pro-
duits inflammables.
D
Ne lever et ne soutenir l’appareil qu’avec de
l’équipement approprié et en suivant les
procédures adéquates.
D
Ne pas surcharger l’installation électrique − s’assurer que l’ali-
mentationest correctement dimensionnée et protégée avant de
mettre l’appareil en service.
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.
OM-492 Page 9
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UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
LE SURCHAUFFEMENT peut endom-
mager le moteur électrique.
D
Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
D
Arrêter ou déconnecter l’équipement avant de
démarrer ou d’arrêter le moteur.
D
Installer convenablement le poste sur la remor-
que comme indiqué dans le manuel s’y rappor-
tant.
D
D
Ne pas laisser tourner le moteur trop lentement sous risque d’en-
dommagerle moteur électrique à cause d’une tension et d’une fré-
quence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,
s’il y a lieu.
LIRE LES INSTRUCTIONS.
D
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D
N’utiliser que les pièces de rechange recom-
mandées par le constructeur.
LES ÉTINCELLES VOLANTES ris-
quent de provoquer des blessures.
D
Effectuer la maintenance et le service du moteur et du compres-
seur d’air suivant les instructions dans ce manuel ou le manuel
du moteur/compresseur (si applicable).
D
Porter un écran facial pour protéger le visage et
les yeux.
D
Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette manœuv-
re est à exécuter dans un endroit sûr lorsque l’on
porte l’équipement homologué de protection du
visage, des mains et du corps.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
D
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipe-
ments de radio−navigation et de communica-
tion, les services de sécurité et les ordinateurs.
D
Les étincelles risquent de causer un incendie − éloigner toute sub-
stance inflammable.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’instal-
lation.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D
D
L’utilisateurest tenu de faire corriger rapidement par un électri-
cien qualifié les interférences résultant de l’installation.
D
Si le FCC signale des interférences, arrêter immédiatement l’ap-
pareil.
D
D
Effectuer régulièrement le contrôle et l’entretien de l’installation.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
Maintenirsoigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une dis-
tance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
D
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D
Ne pas diriger le pistolet vers soi, d’autres per-
sonnes ou toute pièce mécanique en enga-
geant le fil de soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
L’énergie électromagnétique risque de provo-
quer des interférences pour l’équipement élec-
tronique sensible tel que les ordinateurs et
l’équipementcommandé par ordinateur tel que
les robots.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
D
Laisser l’équipement refroidir ; respecter le fac-
teur de marche nominal.
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D
D
Veiller à ce que tout l’équipement de la zone de soudage soit
compatibleélectromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Ne pas obstruer les passages d’air du poste.
D
D
D
Veiller à souder à une distance de 100 mètres de tout équipe-
ment électronique sensible.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les
circuits imprimés.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
mentairestelles que le déplacement du poste, l’utilisation de câ-
bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
teurs dans la zone de travail.
D
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D
Utiliser des pochettes et des boîtes antistatiques pour stocker,
déplacer ou expédier des cartes de circuits imprimes.
OM-492 Page 10
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2-6. Proposition californienne 65 Avertissements
Pour les moteurs à essence :
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal-
formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les gaz d’échappement des moteurs contiennent des pro-
duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi-
ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmesde procréation. Se laver les mains après manipu-
lation.
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com-
me provoquant des cancers et des malformations
congénitalesou autres problèmes de procréation.
2-7. Principales normes de sécurité
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
Internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, de American National Standards Institute,
11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900,site Internet : www.ansi.org).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1 de Global Engineering Documents (téléphone
1-877-413-5184,site Internet : www.global.ihs.com).
:
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).
National Electrical Code, NFPA Standard 70, de National Fire Protec-
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-
tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone: 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-
tilly, VA 20151 (téléphone
www.cganet.com).
:
703-788-2700, site Internet
:
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
CanadianStandards Association, 5060 Mississauga, Ontario, Canada
2-8. Information EMF
Considérationssur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
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 exa-
miné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National
Research 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
conclusions finales de la recherche soient établies, il vous serait
souhaitablede réduire votre exposition aux champs électromagnéti-
ques pendant le soudage ou le coupage.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc-
tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
OM-492 Page 11
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SECTION 3 − DEFINITIONS
3-1. Symbol Definitions
Fast
Fast/Slow
(Run/Idle)
Stop Engine
Slow (Idle)
Fuel
(Run, Weld/Power)
Start Engine
Engine Oil
Engine
Panel/Local
On
Temperature
Check Valve
Clearance
Battery (Engine)
Read Operator’s
Manual
Amperes
Volts
A
V
MIG (GMAW),
Wire
Stick (SMAW)
TIG (GTAW)
Circuit Protector
Touch Start
(GTAW)
Foot Control
Positive
Manual Control
Negative
Pulsed
Output
Alternating Current
(AC)
Protective Earth
(Ground)
Time
Hours
Seconds
s
h
Do not switch while
welding
Remote 14
Receptacle
Work Connection
Glow Plug
14
Electrode
Positive
Wire Feed
Electrode Negative
High Temperature
SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Rated
Welding
Output
Maximum
Open-Circuit
Voltage
Amperage
Range In
CC Mode
Voltage
Range In
CV Mode
Welding
Mode
Generator
Power Rating
Fuel Capacity
Engine
Single-Phase,
12 kVA/kW
100/50 A,
120/240 V AC,
60 Hz
Kubota DH905
Water-Cooled,
Three-Cylinder,
Four-Cycle, 26 HP
Diesel Engine
CC/DC
CV/DC
300 A, 32 V,
60% duty
Cycle
13 gal (49 L)
Tank
99
5 − 375 A
10 − 34 V
OM-492 Page 12
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4-2. Dimensions, Weights, and Operating Angles
Dimensions
A
B
Height
36 in (914 mm)
C
Width
24 in (610 mm)
59 in (1499 mm)
23-5/8 in (600 mm)
21-1/2 in (546 mm)
1 in (25 mm)
!
Do not exceed tilt angles or engine could
be damaged or unit could tip.
Depth
D
Do not move or operate unit where it could
tip.
G
A
B
C
D
E
F
4 Holes
E
F
15-5/8 in (397 mm)
26-3/8 in (679 mm)
58-3/4 in (1492 mm)
13/32 in (10 mm) Dia.
Weight
20°
20°
20°
20°
G
925 lb (420 kg)
Front Panel End
800 426
4-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
60% Duty Cycle
6 Minutes Welding
4 Minutes Resting
Overheating
0
A or V
15
OR
Reduce Duty Cycle
Minutes
sduty1 5/95 / 196 698
OM-492 Page 13
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4-4. Volt-Ampere Curves
Volt-ampere curves show mini-
mum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall be-
tween curves shown.
A. CC Mode
ARC CONTROL
B. CV Mode
178 652 / 178 653
OM-492 Page 14
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4-5. Fuel Consumption
7.57
6.62
5.67
4.73
3.78
2.84
1.98
0.95
2.00
1.75
1.50
1.25
1.00
0.75
0.50
0.25
3600 RPM
IDLE
0
0
50 100 150 200 250 300 350 400 450 500
DC WELD AMPERES AT 100% DUTY CYCLE
193 458
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-492 Page 15
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SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
!
Do not weld on base. Welding
on base can cause fuel tank fire
or explosion. Bolt unit down
using holes provided in base.
Movement
Always securely fasten weld-
ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
ble codes.
Do not lift unit from end.
OR
!
Do not mount unit by support-
ing the base only at the four
mounting holes. Use cross-
supports to adequately sup-
port unit and prevent damage
to base.
Location / Airflow Clearance
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
OR
OR
If unit does not have GFCI re-
ceptacles, use GFCI-protected
extension cord.
18 in
(460 mm)
NOTICE− Do not install unit where air
flow is restricted or engine may over-
heat.
18 in
(460 mm)
18 in
Mounting:
(460 mm)
1
Cross-Supports
Mount unit on flat surface or use
cross-supports to support base.
Grounding:
18 in
(460 mm)
18 in
(460 mm)
2
Equipment Grounding Terminal
(On Front Panel)
3
4
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Mounting
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger insu-
lated copper wire.
OR
Inadequatesupport.
Do not use flexible mounts.
1
Grounding
2
Bed liners, shipping skids, and some running
gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding termi-
nal to bare metal on the vehicle frame as shown.
3
GND/PE
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
install2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712
4
OM-492 Page 16
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5-2. Engine Prestart Checks
Check radiator coolant
level when fluid is low
in recovery tank.
Full
Capacity
w/Overflow Tank
6.4 qt (6 L)
Full
1/2 in
(13 mm)
Full
Diesel
Full
802 330-G
Check all fluids daily. Engine must be cold
and on a level surface. Unit is shipped with
10W30 engine oil.
Engine stops if oil pressure is too low or en-
gine temperature is too high.
Oil
Keep radiator and air intake clean and free
of dirt.
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).
NOTICE − Incorrect engine temperature
can damage engine. Do not run engine with-
out a properly working thermostat and ra-
diator cap.
NOTICE − Engine may use oil and wets-
tacking may occur during run-in period.
Check oil several times daily during run-in.
. This unit has a low oil pressure shut-
down switch. However, some condi-
tions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual. If
unburned fuel and oil collect in exhaust pipe
.
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:
Coolant
Keep battery in good condition. Store
battery in warm area.
Check coolant level in recovery tank before
starting unit the first time. Add coolant if
coolant is below bottom of radiator filler neck
tions.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel
information.
Check coolant in recovery tank daily. If cool-
ant is below Full level, add coolant until cool-
ant level in tank is between Full and Low lev-
els. If recovery tank coolant level was low,
also check coolant level in radiator (see
Fuel
NOTICE − Do not use gasoline. Gasoline
will damage engine.
Use correct grade oil for cold weather
Add fresh diesel fuel before starting engine
the first time (see maintenance label for
specifications).Fill fuel tank up to 1/2 in. (13
mm) from top to allow room for expansion.
Do not run out of fuel or air enters fuel sys-
tem and causes starting problems. See en-
gine manual to bleed air from fuel system.
Engine coolant is a mixture of water and
ethylene glycol base antifreeze. A solution
of 50% antifreeze and 50% water must be
used in this engine. Do not use 100% anti-
freeze or severe damage will occur.
OM-492 Page 17
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5-3. Adding Coolant To Radiator
Stop engine and let cool.
. Check coolant level according
this procedure.
Full
1
If coolant level is below bottom of
radiator filler neck, add coolant as
follows:
Capacity
w/Overflow Tank
6.4 qt (6 L)
1
Radiator Air Bleed Screw
Remove radiator air bleed screw.
Add coolant to radiator until coolant
is at bottom of filler neck. This en-
sures all air is purged from the sys-
tem.
Reinstall screw and radiator cap.
Check coolant level in recovery
Engine coolant is a mixture of water
and ethylene glycol base anti-
freeze. A solution of 50% antifreeze
and 50% water must be used in this
engine.Do not use 100% antifreeze
or severe damage will occur.
Tools Needed:
Ref. 802 330-G
5-4. Connecting The Battery
Connect
negative (−)
cable last.
−
+
Tools Needed:
3/8, 1/2 in
Ref. 213 263-B / 802 330-G / Ref. S-0756-D
OM-492 Page 18
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5-6. Connecting To Weld Output Terminals
Stick And TIG Welding
MIG And FCAW Welding
For Stick welding Direct Current Electrode
Positive (DCEP), connect electrode hold-
er cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on
right.
For MIG welding Direct Current Electrode
Positive (DCEP), connect wire feeder
cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on
right.
For Stick and TIG Direct Current Elec-
trode Negative (DCEN), connect elec-
trode holder cable to Negative (−) terminal
on right and work cable to Positive (+) ter-
minal on left.
For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect wire
feeder cable to Negative (−) terminal on
right and work cable to Positive (+) termi-
nal on left.
!
Stop engine.
1
Positive (+) Weld Output Terminal
Negative (−) Weld Output Terminal
2
Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
3
4
5
6
Weld Output Terminal
Supplied Weld Output Terminal Nut
Weld Cable Terminal
Copper Bar
Remove supplied nut from weld output termi-
nal. Slide weld cable terminal onto weld output
terminaland secure with nut so that weld cable
terminal is tight against copper bar. Do not
place anything between weld cable termi-
nal and copper bar. Make sure that the sur-
faces of the weld cable terminal and cop-
per bar are clean.
Tools Needed:
3/4 in
1
2
6
3
Do not place
anything between
weld cable terminal
and copper bar.
4
5
Correct Installation
Incorrect Installation
80801 941 / Ref. 213 263-B / 802 174-E / 803 778-A
OM-492 Page 20
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5-7. 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)
10 − 60% 60 − 100%
Welding
Amperes
Duty
Duty
10 − 100% Duty Cycle
Cycle
Cycle
Weld Output
Terminals
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)
!
!
Turn off power before
connecting to weld
output terminals.
2/0 (70)
1/0 (60)
3/0 (95) 4/0 (120) 4/0 (120)
Do not use worn,
2 ea. 2/0 2 ea. 2/0
250
300
350
2 (35)
1 (50)
1 (50)
1/0 (60)
2/0 (70)
1/0 (60)
2/0 (70)
3/0 (95)
2/0 (70)
3/0 (95) 4/0 (120)
damaged,
under-
poorly
(2x70)
(2x70)
sized,
or
spliced cables.
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0
(2x70) (2x95) (2x95)
3/0 (95) 4/0 (120)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0
1/0 (60)
4/0 (120)
(2x70)
(2x95)
(2x95)
(2x120)
* This chart is a general guideline and may not suit all applications. If cable(s) overheat, 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.
2
( ) = mm for metric use
S-0007-F
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
5-8. Remote 14 Receptacle RC14 Information
.
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Socket*
Socket Information
A
24 volts ac. Protected by supplementary protector
CB6.
24 VOLTS AC
115 VOLTS AC
B
I
Contact closure to A completes 24 volts ac
contactor control circuit.
A
J
115 volts ac. Protected by supplementary protec-
tor CB5.
K
I
B
C
L
N
H
J
C
Contact closure to I completes 115 volts ac
contactor control circuit.
M
D
G
F
E
Output to remote control; 0 to +10 volts dc, +10
volts dc in MIG mode.
D
E
Remote control circuit common.
REMOTE
OUTPUT
CONTROL
0 to +10 volts dc input command signal from
remote control.
M
F
CC/CV select.
Current feedback; +1 volt dc per 100 amperes.
A/V
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt dc per 10 output recep-
tacle volts.
G
K
Circuit common for 24 and 115 volts ac circuits.
Chassis common.
802 174-G
GND
*The remaining sockets are not used.
OM-492 Page 21
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5-9. Guidelines For Installing Customer-Supplied Emergency Air Shutdown Valve
A customer-supplied emergency air shutdown
valve can be installed to stop the engine imme-
diately in emergency situations.
These guidelines show the typical installation of
a Gator ESD 175-275-L3 air shutdown valve.
Installation of other air shutdown valves may
differ from that shown. Contact the air shut-
down valve manufacturer or a Factory Autho-
rized Service Agent for additional installation
and operation information.
Stop engine, and let cool.
Disconnect battery negative (−) cable.
Open doors and remove side panels.
1
2
3
4
Air Cleaner
2 in (51 mm) Hose Clamp
1-3/4 x 2 in (44 x 51 mm) Rubber Hose
Air Shutdown Valve
(Gator ESD 175-275-L3)
5
1-3/4 x 16-1/2 in (44 x 419 mm) Flexible
Radiator Hose (NAPA Part No. FM68)
. Use thick-walled rubber hose. Do not use
heater hose. (Heater hose could let dirt into
engine.)
6
7
8
Engine Air Inlet
Shutdown Control
7
42 in (1067 mm) Shutdown Control Cable
(Supplied By Gator)
9
Shutdown Valve Reset Lever
Install components as shown.
Be sure air shutdown valve is installed with air
flow arrow pointing toward air inlet. Use cable
ties to keep air shutdown system components
away from hot or moving parts.
Verify the emergency air shutdown system op-
erates correctly. After testing, use reset lever to
reset air shutdown valve.
Reinstall side panels and close doors.
Reconnect battery negative (−) cable.
1
2
8
3
4
Mount on lower
front panel
9
5
7
6
803 390
OM-492 Page 22
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5-10.Operating Engine Block Heater
!
Do not touch hot engine
block. Engine block gets hot
near heater.
NOTICE − Do not run engine while
coolant heater is on.
1
1
2
Coolant Heater
Heater Plug
2
Use heater to maintain a constant
engine coolant temperature. See
table for heater specifications.
To turn on heater, connect heater
plug to a 120 volt ac grounded re-
ceptacle.
To turn off heater, disconnect plug.
Coolant Heater Specifications
Watts
Volts 10%
Amps
400
120
3.3
Ref. 802 330 / 803 393
Notes
Start Your Professional
Welding Career Now!
Over 80,000 trained
since 1930!
400 Trade Square East, Troy, Ohio 45373
OM-492 Page 23
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mode switch. Inductance determines the
Engine Starting Controls
12 Glow Plug Switch
Use switch to energize glow plugs for cold
weather starting. Glow plugs warm in about
six seconds and engine can be started (see
starting instructions following).
. The fan motor is thermostatically
controlled and only runs when cooling is
needed.
“wetness” of the weld puddle. When set to-
ward maximum, “wetness” (puddle fluidity) in-
creases.
Engine Lights
Control is not functional when Pulsed MIG or
one of the TIG modes is selected.
1
Engine Temperature Light
Light goes on and engine stops if engine tem-
perature is too high.
7
Voltmeter
NOTICE − Do not use glow plug longer than
20 seconds.
13 Engine Control Switch
Use switch to start engine, select speed, and
stop engine. In Run/Idle position, engine runs
at idle speed at no load, and weld/power
speed under load. In Run position, engine
runs at weld/power speed.
Meter displays weld voltage and help mes-
NOTICE − Stop engine and fix trouble if En-
gine Temperature light goes on.
8
Ammeter
2
Engine Oil Pressure Light
Meter displays weld amperage and help mes-
Light goes on and engine stops if oil pressure
is too low. Light goes on momentarily during
start-up but goes out when engine reaches
normal oil pressure.
9
V/A (Voltage/Amperage) Adjustment
Control
To Start:
10 Mode Switch
NOTICE − Stop engine and fix trouble if En-
gine Oil Pressure light stays on after start-up.
NOTICE − Do not use ether as a starting aid.
Using ether voids warranty.
The Mode switch setting determines both the
process and output On/Off control (see Sec-
tion 6-4). Source of control (panel or remote)
for the amount of output is selected by the V/A
Control switch.
3
Battery Charging Light
Above 325 F: turn Engine Control switch to
Start. Release switch when engine starts and
Engine Oil Pressure light goes out.
Light goes on if engine alternator is not charg-
ing battery. Engine continues to run.
NOTICE − Stop engine and fix trouble if Bat-
. If engine does not start, let engine come
to a complete stop before attempting re-
start.
For Air Carbon Arc (CAC-A) cutting and goug-
ing, place switch in Stick position. For best re-
sults, place Dig/Inductance control in the max-
imum position.
tery Charging light goes on.
Engine Gauges
Below 325 F: turn engine control switch to
Run/Idle position. Push Glow Plug switch up
and hold about six seconds. Turn Engine Con-
trol switch to Start. Release switch when en-
gine starts and Engine Oil Pressure light goes
out.
4
Engine Hour Meter
11 V/A (Voltage/Amperage) Control Switch
And Remote 14 Receptacle
Use hour meter to help schedule routine main-
tenance.
For front panel control, place switch in Panel
position and use the V/A Adjustment control.
5
Fuel Gauge
Weld Controls
For remote control, make connections to Re-
place switch in Remote position. In most
modes, remote control is a percent of V/A Ad-
justment control setting (value selected on
V/A Adjustment control is maximum available
on remote). In the MIG mode, remote control
provides full range of unit output regardless of
V/A Adjust control setting.
6
Dig/Inductance Control
cold weather operation.
Control adjusts Dig when Stick mode is se-
lected on mode switch. When control is set to-
ward minimum, short-circuit amperage at low
arc voltage is the same as normal welding
amperage.
. If engine does not start, let engine come
to a complete stop before attempting re-
start.
To Stop: turn Engine Control switch to Off
position.
When set toward maximum, short-circuit am-
perage is increased at low arc voltage to as-
sist with arc starts and help prevent the elec-
trode from sticking while welding (see volt-am-
. Push engine stop lever to stop engine if
Engine Control switch does not work (see
Select setting best suited for application.
14 Engine Stop Lever
Control adjusts inductance when MIG or
V-Sense Feeder position is selected on the
Use lever to stop engine if Engine Control
switch does not work.
OM-492 Page 25
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6-3. Meter Functions
.
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.
Mode
Meter Reading At Idle
Meter Reading While Welding
V
A
V
A
Scratch
Start TIG
80.0
Actual Volts (OCV)
V
85
Preset Amps
A
10.3
Actual Volts
V
85
Actual Amps
A
Lift-Arc TIG
TIG
7.0
Actual Volts
V
85
Preset Amps
A
10.3
Actual Volts
V
85
Actual Amps
A
85
Preset Amps
A
10.3
Actual Volts
V
85
Actual Amps
A
Blank
V
MIG
24.5
Preset Volts
V
24.5
Actual Volts
V
250
Actual Amps
A
Blank
A
Pulsed
MIG
PPP
Pulse Display
V
PPP
Pulse Display
A
24.5
Actual Volts
V
250
Actual Amps
A
CC
85
Preset Amps
A
24.5
Actual Volts
V
85
Actual Amps
A
Blank
V
Stick
80.0
Actual Volts (OCV)
V
85
Preset Amps
A
24.5
Actual Volts
V
85
Actual Amps
A
V-Sense
Feeder
80.0
24.5
250
Flashes OCV And Preset
Blank
Actual Volts
Actual Amps
6-4. Mode Switch Settings
.
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the start require it. This eliminates electrode sticking at arc start.
Mode Switch Setting
Scratch Start TIG
Lift-Arc TIG
TIG
Process
GTAW
Output On/Off Control
Electrode Hot
Electrode Hot
At Remote 14
At Remote 14
At Remote 14
At Remote 14
Electrode Hot
Electrode Hot
GTAW With HF Unit, Pulsing Device, Or Remote Control
GMAW
MIG
Pulsed MIG
CC
GMAW-P (Requires an external pulsing device.)
Stick (SMAW) With Remote On/Off
SMAW
Stick
V-Sense Feeder
MIG (GMAW) With Voltage Sensing Wire Feeder
OM-492 Page 26
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6-5. Lift-Arc TIG Procedure
With Mode Switch in the Lift-Arc
TIG position, start an arc as follows:
1
2
TIG Electrode
Workpiece
1
2
Touch tungsten electrode to work-
piece at weld start point, hold
electrode to workpiece for 1-2
seconds, and slowly lift electrode.
An arc will form when electrode is
lifted.
1 − 2
“Touch”
Seconds
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece with-
out overheating, sticking, or getting
contaminated.
Do NOT Strike Like A Match!
Ref. S-156 279
6-6. Recommendations For Extreme Cold Weather Operation
D
A 50/50 antifreeze/water mix protects en-
gine to -34°F (−37°C). If operating at even
lower temperatures, contact a Factory
AuthorizedService Agent or Kubota Ser-
vice Center for coolant information.
Operating
. For more information on operating in cold
weather, contact the nearest Factory Au-
thorized Service Agent or Kubota Service
Center.
D
To reduce crankcase condensation and
breather tube freezing problems, allow
engineto reach normal operating temper-
ature as quickly as possible.
Fuel
Battery
D
Use an arctic-grade diesel fuel and keep
fuel tank at least half full to prevent fuel
lines from draining back into tank.
D
Crankcase breather tubes will collect
condensationand freeze if the hose is im-
properly routed. The breather tube should
be free of sharp bends and kinks. A
blocked breather tube will cause exces-
sive crankcase pressure that will blow out
the safety plug, oil seals, or dipstick. Con-
tact a Factory Authorized Service Agent
to obtain a shorter breather hose that is
less likely to kink.
D
ReplacementBattery Rating: 12 Volt, 535
CCA (minimum) 90 RSV Group 55.
D
Do not use gasoline or kerosene.
Do not use fuel additives.
D
Check connections at battery, starter, and
engine block. Inspect battery cables for
abrasion and wear, and verify the battery
is secured.
D
Oil
D
Use 10W30 oil when operating at ambient
temperaturesabove -4° F (−20° C).
D
D
Consider installing easily-accessible bat-
tery booster leads (0 or 00 AWG) to pro-
vide easy connection to a service truck’s
battery.
D
D
Inspect the routing and condition of the
breather tube frequently. Reroute or re-
place the hose if necessary.
D
D
Use 5W30 oil when operating at ambient
temperatures above -13° F (−25° C).
Boost the starting capability of the battery
by using a battery heater.
Operating at extremely low temperatures
thickens engine oil and reduces cranking
speed. Contact a Factory Authorized Ser-
vice Agent or Kubota Service Center for
information on using 0W20 oil in these
conditions. Low temperature oil must be
replaced as ambient operating tempera-
tures increase.
For continuous use in extreme cold, block
the cooling holes in the base to reduce air
flow through the radiator and achieve
higher engine temperature. Close off the
base inlet vents only if the engine coolant
or oil temperatures can be monitored to
ensure they remain within the specified
limits.
Starting
D
D
Do not use ether.
Use the engine block heater to maintain
engine temperature above ambient tem-
perature.
Coolant
D
D
To obtain warmer air for combustion, turn
the air cleaner inlet away from the inlet
vents, and seal the inlet vents.
D
D
Use the glow plugs for 20−30 seconds be-
fore starting. As a preseason check,
make sure the glow plugs are working
properly.
D
Be sure the cooling system is completely
filled with a 50/50 antifreeze/water mix
(open the radiator vent when filling). Do
not mix antifreeze and water solution in
the overflow tank. Use a premixed 50/50
antifreeze/watersolution to “top off” over-
flow tank. Use caution if rerouting cooling
lines. Engine damage due to lack of
coolant or incorrect coolant mix is not
covered by the warranty.
If operating in cold weather all the time,
consider replacing the existing radiator
cooling fan with a smaller fan that draws
less air through the radiator. Operation in
warmer temperatures would require an
additional “booster” electric fan to ade-
quately cool the engine.
Disconnect all unnecessary loads from
generator ac receptacles when starting.
OM-492 Page 27
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SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. Generator Power Receptacles And Circuit Breakers
7
5
1
2
3
6
4
8
SIMULTANEOUS WELDING AND AUXILIARY POWER
Weld
Total
Power
In Watts
120 V
Receptacle
Amperes
Single-Phase Three-Phase
240 V 240 V
Current
In Amperes
Receptacle Receptacle
Amperes
Amperes
350
300
250
200
150
100
50
11900
9600
7500
5600
3900
2400
1100
0
−
−
−
16
38
40
40
40
40
40
5
4
15
30
35
40
45
50
10
13
19
23
26
30
0
213 263-B
put from RC2 or RC3 is 2.4 kVA/kW.
7
Supplementary Protector CB4
If unit does not have GFCI recep-
tacles, use GFCI-protected exten-
sion cord.
4
240 V 30 A, AC Twistlock Receptacle
RC4
CB4 protects RC4 from overload. If CB4
opens, the receptacle does not work. Place
switch in On position to reset.
RC4 supplies 60 Hz three-phase power at
weld/power speed. Maximum output is 12
kVA/kW.
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
d
e
c
r
e
a
s
e
s
a
s
w
e
l
d
current increases.
. If a supplementary protector continues
to open, contact Factory Authorized
Service Agent.
1
240 V 50 A AC Receptacle RC1
5
Supplementary Protector CB1
CB1 protects RC1, RC2, and RC3 from
overload. If CB1 opens, RC1, RC2, and
RC3 do not work. Place switch in On posi-
tion to reset.
RC1 supplies 60 Hz single-phase power at
weld/power speed. Maximum output is 12
kVA/kW.
Combined output of all receptacles limited
to 12 kVA/kW rating of the generator.
EXAMPLE: If 13 A is drawn from RC2 and
RC3, only 37 A is available at RC1:
2
120 V 20 A AC Duplex Receptacle
RC2
6
Supplementary Protectors CB2 And
CB3
3
120 V 20 A AC Duplex Receptacle
RC3
2 x (120 V x 13 A) + (240 V x 28 A) = 12
kVA/kW
CB2 protects RC2 and CB3 protects RC3
from from overload. If CB2 or CB3 opens,
the receptacle does not work. Press button
to reset.
RC2 and RC3 supply 60 Hz single-phase
power at weld/power speed. Maximum out-
8
Generator Power While Welding
Table
OM-492 Page 28
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7-2. Optional GFCI Receptacles And Circuit Breakers
If unit does not have GFCI
receptacles, use GFCI-pro-
tected extension cord.
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
d
e
c
r
e
a
s
e
s
a
s
1
2
weld current increases.
1
2
120 V 20 A AC GFCI Duplex
Receptacle GFCI-2
120 V 20 A AC GFCI Duplex
Receptacle GFCI-3
GFCI-2 and GFCI-3 supply 60 Hz
single-phase power at weld/power
speed. Maximum output from
GFCI-2 or GFCI-3 is 2.4 kVA/kW.
Circuit protection is the same as
standard receptacles.
If a ground fault is detected, the GFCI
Reset button pops out and the circuit
opens to disconnect the faulty equip-
ment. Check for damaged tools,
cords, plugs, etc. connected to the
receptacle. Press button to reset re-
ceptacle and resume operation.
. At least once a month, run en-
gine at weld/power speed and
press Test button to verify GFCI
is working properly.
Ref. ST-207 554-A
7-3. Wiring Instructions For Optional 240 Volt, 3-Phase Twistlock Plug (NEMA L15-30P)
1
240 V AC Three-Phase, 30 A,
3P4W Twistlock Plug
1
2
3
4
5
6
Load 1 (Brass) Terminal (X)
Load 2 (Brass)Terminal (Y)
Load 3 (Brass) Terminal (Z)
Ground (Green) Terminal (G)
Cord Grip
5
4
Strip cord jacket back enough to sep-
arate conductors.
Strip conductors enough to make
good contact with plug terminals.
Make plug connections and reinstall
cord grip.
2
240V
240V
240V
3
6
Tighten cord grip assembly screws.
Do not overtighten.
Tools Needed:
Plug2 7/99 − 802 437
OM-492 Page 29
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7-4. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)
The plug can be wired for a 240 V,
2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
1
Plug Wired for 120/240 V,
3-Wire Load
7
Current Available in Amperes
When wired for 120 V loads, each
duplex receptacle shares a load
with one half of 240 V receptacle.
240 V
Receptacle*
Each 120 V Duplex
Receptacle
2
Plug Wired for 240 V, 2-Wire
Load
0
5
20
20
20
20
20
15
10
5
1
3
3
4
5
6
7
Neutral (Silver) Terminal
Load 1 (Brass)Terminal
Load 2 (Brass) Terminal
Ground (Green) Terminal
4
10
15
20
25
30
35
40
Amperes Available using
120/240 V Plug
120V
5
120V
0
240V
6
V x A = Watts
Tools Needed:
*One 240 V load or two 120 V loads.
2
3
4
240V
6
5
240 V AC
120 V AC
120 V AC
plug1 11/03 − 120 813-D
OM-492 Page 30
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8-2. Routine Maintenance
Stop engine before maintaining.
. See Engine Manual and Maintenance Label
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
Recycle engine
fluids.
n
=
C
h
e
c
k
Z
=
C
h
a
n
g
e
~
=
C
l
e
a
n
l
=
R
e
p
l
a
c
e
Reference
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * To be done by Factory Authorized Service Agent
Every
8
Section 5-6
Hours
n
C
o
o
l
a
n
t
L
e
v
e
l
n
F
u
e
l
L
e
v
e
l
n
O
i
l
L
e
v
e
l
~
O
i
l
,
F
u
e
l
S
p
i
l
l
s
Every
50
Hours
n
F
u
e
l
C
o
n
n
e
c
t
i
o
n
s
~ Weld Terminals
n Air Cleaner Hoses
Z Oil Filter
~
Spark Arrestor Screen
Every
100
Hours
Engine
Manual
5/16 in.
(8 mm)
~
A
i
r
C
l
e
a
n
e
r
E
l
e
m
e
n
t
n
B
e
l
t
T
e
n
s
i
o
n
~
B
a
t
t
e
r
y
T
e
r
m
i
n
a
l
s
Every
200
Hours
Z
O
i
l
n
R
a
d
i
a
t
o
r
H
o
s
e
s
l
U
n
r
e
a
d
a
b
l
e
L
a
b
e
l
s
Z Primary Fuel Filter
Z Secondary Fuel Filter
Every
400
Hours
Every
500
Hours
Engine
Manual,
FUEL
SLUDGE
l
F
a
n
B
e
l
t
~
F
l
u
s
h
R
a
d
i
a
t
o
r
n
l
W
e
l
d
C
a
b
l
e
s
n
~
Drain Sludge
Every
800
Hours
Engine
Manual
n
V
a
l
v
e
C
l
e
a
r
a
n
c
e
*
Every
1000
Hours
OR
~
I
n
s
i
d
e
U
n
i
t
n
n
~
S
l
i
p
R
i
n
g
s
*
l
Brushes*
Every
2000
Hours
Engine
Manual
n
l
C
o
o
l
a
n
t
A
n
d
H
o
s
e
s
l
Fuel Lines And Clamps
OM-492 Page 32
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8-3. Servicing Spark Arrestor
Stop engine and let cool.
1
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
Start engine and run several min-
utes to blow out cleanout hole. If
nothing blows out of hole, briefly
cover end of exhaust pipe with fire-
proof material.
1
Tools Needed:
1/4 in
Ref. 213 263-B-B / 802 743 / Ref. 802 656
OM-492 Page 33
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8-4. Servicing Air Cleaner
Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damagecaused by using a damaged ele-
ment is not covered by the warranty.
1
3
4
2
. The air cleaner primary element can
be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.
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.
1
2
3
4
5
Housing
Keep nozzle
2 in (51 mm)
from element.
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
NOTICE − Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-492 Page 34
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8-5. Servicing Engine Lubrication And Fuel Systems
4
FLOW
5
4
6
1
7
3
8
Tools Needed:
2
9/16 in
Ref. 213 263-B / 802 330-G / S-0842
To drain water from fuel system:
To change coolant:
Stop engine and let cool.
Oil Filter
1
2
3
4
5
6
7
8
Open secondary fuel filter petcock and
drain water into metal container. Close pet-
cock when water-free fuel flows.
Change coolant according to engine
manual.
Oil Drain Valve
1/2 ID x 12 in Hose
Fuel Line
To change fuel filters:
Run engine until engine reaches normal op-
erating temperature. Loosen air bleed
screw to remove air from cooling system.
Tighten screw.
Primary Fuel Filter
Secondary Fuel Filter
Petcock
Install new primary fuel filter as shown.
Replace secondary fuel filter according to
engine manual.
Fuel Tank Sludge Drain
Check coolant level in recovery tank. Add
coolant if necessary.
To change oil and filter:
Replace fuel lines if cracked or worn.
Wipe up any spilled fuel.
Pull oil drain hose through access hole in
base. Change engine oil and filter according
to instructions in engine manual.
To drain sludge from fuel tank:
After servicing, start engine and
check for fuel leaks.
NOTICE − Close valve and valve cap be-
fore adding oil and running engine.
Put metal container under drain, and re-
move sludge drain plug. Reinstall plug
when done.
Fill crankcase with new oil to full mark on
Stop engine, tighten connections as
necessary, and wipe up fuel.
OM-492 Page 35
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8-6. Servicing Engine Cooling System
!
Stop engine and let cool.
Radiator Draincock
Radiator Cap
1
2
3
Radiator Air Bleed Screw
Change coolant according to engine
manual. Add coolant according to Sec-
Run engine until engine reaches normal
operating temperature. Loosen air bleed
screw to remove air from cooling system.
Tighten screw.
Check coolant level in recovery tank. Add
coolant if necessary
1
3
2
802 330-G / 802 581
OM-492 Page 36
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8-7. Replacing Throttle Solenoid TS1
!
!
Stop engine, and let cool.
Disconnect battery, negative
(−) cable first.
Remove right side engine panel.
1
2
3
4
5
6
7
8
Plug PLG39/Receptacle RC39
Throttle Solenoid TS1
Shoulder Bolt And Nut
Throttle Link
Throttle Solenoid Plunger Rod
Jam Nut
Throttle Arm
Throttle Arm Stop Screw
Disconnect solenoid plug PLG39
from wiring harness receptacle
RC39.
Remove shoulder bolt and nut from
throttle link.
Remove solenoid from mounting
bracket.
Note how much thread is visible on
solenoidplunger rod. Loosen jam nut
just enough so throttle link can be re-
moved from solenoid rod.
Install throttle link on new solenoid
plunger rod. Turn link until the same
amount of thread will be visible on
plungerrod when the jam nut is tight-
ened. (Do not tighten jam nut yet.)
Mount solenoid on bracket. Move so-
lenoid plunger manually to align slot
in throttle link with hole in throttle arm.
Insert shoulder bolt through slot/hole
and secure with nut.
1
. Be sure solenoid plunger rod
pulls all the way in “bottoms”
when energized. If plunger rod
does not pull all the way in, re-
adjust throttle link.
8
. Throttle arm should not contact
stop screw when solenoid is en-
ergized. If necessary, adjust
stop screw to create gap be-
tween throttle arm and stop
screw.
2
7
Tighten jam nut on solenoid plunger
rod. Verify all other hardware is tight.
Connect solenoid plug PLG39 to wir-
ing harness receptacle RC39.
Reconnect battery, negative (−) lead
last.
Check engine speeds and adjust if
Reinstall side panel.
5
6
4
3
Tools Needed:
7/16, 3/8, 1/2 in
10 mm
3/16 in
802 330-B
OM-492 Page 37
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8-8. Adjusting Engine Speed
After tuning engine, check engine
speeds with a tachometer (see table).
If necessary, adjust speeds as follows:
Start engine and run until warm. Turn
V/A control to max.
2500 rpm (41.6 Hz)
3750 Max (62.5 Hz)
Adjusting Idle Speed
Idle speed is factory set and normally
does not not require adjustment unless
the governor/injector pump or throttle
solenoid is replaced.
1
2
3
4
Throttle Link
Throttle Solenoid Plunger Rod
Jam Nut
Throttle Arm Stop Screw
Turn Engine Control switch to Run/Idle
position. Loosen jam nut and turn sole-
noid rod clockwise (into throttle link) to
decrease idle speed. Turn rod counter-
clockwise to increase idle speed.
Tighten nut.
. Be sure solenoid plunger rod pulls
all the way in “bottoms” when en-
ergized. If plunger rod does not
pull all the way in, readjust rod and
throttle link.
. Throttle arm should not contact
stop screw when solenoid is ener-
gized. If necessary, adjust stop
screw to create gap between
throttle arm and stop screw.
Adjusting Weld/Power Speed
5
6
7
Throttle Solenoid
Weld Speed Jam Nut
Adjustment Screw
Turn Engine Control switch to Run
position. Loosen nut and turn screw
counterclockwise to increase speed.
Turn screw clockwise to decrease
speed. Tighten nut.
6
Using Engine Stop Lever
7
8
Engine Stop Lever
Use lever to stop engine if Engine Con-
trol switch does not work.
4
5
8
2
3
1
Tools Needed:
10 mm
802 330-B
OM-492 Page 38
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8-9. Overload Protection
Stop engine.
Tools Needed:
3/8 in
.
W
h
e
n
a
s
u
p
p
l
e
m
e
n
t
a
r
y
p
r
o
t
e
c
-
tor or circuit breaker opens, it
usually indicates a more seri-
ous problem exists. Contact
Factory Authorized Service
Agent.
1
SupplementaryProtector CB5
CB5 protects the 115 volt ac output
to Remote 14 receptacle RC14. If
CB5 opens, 115 volt ac output to
RC14 stops.
2
Supplementary Protector CB6
CB6 protects the 24 volt ac output
to Remote 14 receptacle RC14. If
CB6 opens, 24 volt ac output to
RC14 stops.
Press button to reset.
1
2
3
4
5
Circuit Breaker CB7
Circuit Breaker CB8
Supplementary Protector
CB10
CB7 protects the engine glow plug
from overload. If CB7 opens, the
glow plug does not work and engine
may not start in cold weather.
Check continuity and connections
of engine glow plug.
CB8 protects the engine wiring sys-
tem from overload. If CB8 opens,
the engine will not crank. Check
battery, starter, and engine control
switch.
CB10 protects the engine fuel sole-
noid from overload. If CB10 opens,
the engine cranks but does not
start. Check fuel solenoid FS1 for
obstructions.
5
4
3
Ref. 213 263-B-B / 802 174-E / 802 175-D
OM-492 Page 39
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8-10.Voltmeter/Ammeter Help Displays
V
A
V
A
1
6
HE.L P−0 HE.L P−5
V
A
V
A
2
7
HE.L P−1 HE.L P−6
V
A
V
A
3
4
5
8
HE.L P−2 HE.L P−7
V
A
V
A
9
HE.L P−3 HE.L P−8
V
A
V
A
10
HE.L P−4 HE.L P−9
802 174-G
Use the voltmeter/ammeter help displays to
help determine the cause of no weld output.
When a help display is shown, the inverter
module weld output has stopped but the en-
gine continues to run. Correct the problem
before resuming operation.
3
Help 2 Display
7
Help 6 Display
Indicates that the input voltage is too low and
the unit has automatically shut down. Opera-
tion will continue when the voltage is within the
acceptable lower range limit (15% below the
applicable input voltage). If this display is
shown, have a Factory Authorized Service
Agent check the power generator output volt-
age.
Indicates a malfunction in the thermal protec-
tion circuitry located on the left side of the unit.
If this display is shown, contact a Factory Au-
thorized Service Agent.
The display screen resets when the fault is
corrected.
4
Help 3 Display
Indicates the left side of the unit has over-
heated. The unit has shut down to allow the
continue when the unit has cooled.
8
Help 7 Display
. All directions are in reference to the front
of the unit. All circuitry referred to is lo-
cated inside the inverter module.
Indicates that the input voltage is too high and
the unit has automatically shut down. Opera-
tion will continue when the voltage is within the
acceptableupper range limit (15% above the
applicable input voltage). If this display is
shown, have a Factory Authorized Service
Agent check the power generator output volt-
age.
5
Help 4 Display
1
Help 0 Display
Indicates a malfunction in the thermal protec-
tion circuitry located on the right side of the
unit. If this display is shown, contact a Factory
Authorized Service Agent.
Indicates a shorted thermistor RT2 on the left
side of the unit. If this display is shown, con-
tact a Factory Authorized Service Agent.
9
Help 8 Display
Indicatesa malfunction in the secondary pow-
er circuit of the unit. If this display is shown,
contact a Factory Authorized Service Agent.
2
Help 1 Display
6
Help 5 Display
Indicates a malfunction in the primary power
circuit possibly caused by applying a high
weld load at idle speed. Turn Engine Control
10 Help 9 Display
Indicates the right side of the unit has over-
heated. The unit has shut down to allow the
Indicates a shorted thermistor RT1 on the
right side of the unit. If this display is shown,
contact a Factory Authorized Service Agent.
contact a Factory Authorized Service Agent.
continue when the unit has cooled.
OM-492 Page 40
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8-11. Troubleshooting
A. Welding
Trouble
Remedy
No weld output.
Check control settings.
Check weld connections.
Disconnect equipment from generator power receptacles during start-up.
If using remote control, be sure mode switch is in a position that provides output control at Remote 14
Check, repair, or replace remote control.
Have Factory Authorized Service Agent check brushes, slip rings, power board PC7, voltage regulator
board PC8, interconnecting board PC2, and control board PC1.
Ammeter and voltmeter do not work
after unit has run out of fuel.
Restart the engine.
Low weld output.
Check control settings.
Place V/A Control switch in Panel position, or move switch to Remote position and connect remote
If using remote control, be sure mode switch is in a position that provides output control at Remote 14
Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, intercon-
necting board PC2, and control board PC1.
See engine manual.
High weld output.
Check control settings.
Check for obstructed movement of throttle solenoid linkage.
Have Factory Authorized Service Agent check voltage regulator board PC8 and control board PC1.
Have Factory Authorized Service Agent check voltage regulator board PC8 and control board PC1.
Check control settings.
Weld output cannot be adjusted.
Erratic weld output.
Clean and tighten connections both inside and outside unit.
Check and secure lead connections to A/V control.
Be sure connection to work piece is clean and tight.
Remove excessive coils from weld cables.
Use dry, properly stored electrodes.
Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, intercon-
necting board PC2, and control board PC1.
OM-492 Page 41
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Trouble
Remedy
Remote contactor control does not
activate contactor.
Lack of high frequency; difficulty in
establishing Gas Tungsten Arc Weld-
ing arc.
Use proper size tungsten for welding amperage.
Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive
coils from weld cables, use shorter weld cables, etc.).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Wandering arc − poor control of arc
direction.
Reduce gas flow rate.
Select proper size tungsten. Properly prepare tungsten.
Shield weld zone from drafts.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
ceptacle RC14.
No 24 volt ac output at Remote 14 re-
ceptacle RC14.
B. Generator Power
Trouble
Remedy
No power output.
Have Factory Authorized Service Agent check brushes, slip rings, power board PC7, voltage regulator
board PC8, interconnecting board PC2, and control board PC1.
Low power output.
Check air cleaner, and clean or replace element if necessary.
See engine manual.
High power output.
Check receptacle wiring and connections.
Erratic power output.
Check governor according to engine manual.
Have Factory Authorized Service Agent check brushes, slip rings, power board PC7, voltage regulator
board PC8, interconnecting board PC2, and control board PC1.
OM-492 Page 42
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C. Engine
Trouble
Remedy
Engine will not crank.
Check battery voltage.
Check battery connections and tighten if necessary.
Have Factory Authorized Service Agent check Engine Control switch S2.
Engine cranks, but does not start.
Check oil level (see Section 5-2). Engine will not start if oil pressure is low.
Check coolant level and fan belt (see Section 5-2 and engine manual). Engine will not start if coolant
temperature is high.
Use Glow Plug switch if unit does not start in cold weather. If unit still does not start, reset circuit
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Bleed air from fuel system according to engine manual.
Have Factory Authorized Service Agent check low oil pressure switch S5, engine coolant tempera-
ture switch S4, and control relay CR1.
See engine manual.
Engine starts, but stops when Engine
Control switch returns to Run position.
Check oil level (see Section 5-2). Engine will not start if oil pressure is too low.
Check coolant level and fan belt (see Section 5-2 and engine manual). Engine will not start if engine
temperature is too high.
Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see en-
gine manual).
Have Factory Authorized Service Agent check low oil pressure switch S5, engine coolant tempera-
ture switch S4, Engine Control switch S2, control relay CR1, and voltage regulator board PC8.
Engine does not stop.
5-2). After stopping engine, adjust fuel solenoid linkage (see engine manual).
Engine stopped during normal
operation.
Check oil level (see Section 5-2). Engine stops if oil pressure is too low.
Check coolant level and fan belt (see Section 5-2 and engine manual). Engine stops if engine temper-
ature is too high.
Bleed air from fuel system according to engine manual.
Have Factory Authorized Service Agent check low oil pressure switch S5 and engine coolant temper-
ature switch S4.
Battery discharges between uses.
Clean top of battery with baking soda and water solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Replace battery.
Check voltage regulator according to engine manual.
OM-492 Page 43
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Trouble
Remedy
Engine does not go to low (idle) speed Be sure Engine Control switch S2 is in Run/Idle position.
with Engine Control switch in Run/Idle
position.
Remove all weld and generator power loads.
Check for obstructed movement of throttle solenoid linkage.
Have Factory Authorized Service Agent check voltage regulator board PC8 and current transformer
CT1.
Engine does not go to high (run) speed Place Engine Control switch in the Run position. Have Factory Authorized Service Agent check unit.
when generator power or large weld
load is applied with Engine Control
switch in Run/Idle position.
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine (see Section 10 and engine manual).
Coolant recovery tank continuously
overflows.
Notes
OM-492 Page 44
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Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-492 Page 45
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212 633-F
OM-492 Page 47
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SECTION 10 − RUN-IN PROCEDURE
run_in4 2007−05
10-1. Wetstacking
!
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
2
1
Welding Generator
Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
. Do not idle engine longer than
necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generatoris kept loaded during
run-in.
1
2
Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for addition-
al engine run-in information.
OM-492 Page 48
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10-2. Run-In Procedure Using Load Bank
!
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
!
Keep exhaust and pipe away
from flammables.
4
NOTICE − Do not perform run-in
procedureat less than 20 volts weld
output and do not exceed duty
cycle or equipment damage may
occur.
2
1
1
Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2
3
Welding Generator
Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe
polarity.
correct
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator V/A control so load
equals 225 amps at 30 volts.
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generatoris loaded properly.
3
.
C
h
e
c
k
o
i
l
l
e
v
e
l
f
r
e
q
u
e
n
t
l
y
d
u
r
-
ing run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place V/A control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.
Stop engine and let cool.
4
Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0683
OM-492 Page 49
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10-3. Run-In Procedure Using Resistance Grid
!
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
6
!
Keep exhaust and pipe away
from flammables.
2
NOTICE − Do not perform run-in
procedureat less than 20 volts weld
output and do not exceed duty
cycle or equipment damage may
occur.
1
Resistance Grid
Use grid sized for generator rated
output.
1
Turn Off grid.
2
3
Welding Generator
Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connec-
tors (polarity is not important).
4
5
Voltmeter
Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several
minutes.
Set grid switches and then adjust
generator V/A control so load
equals 225 amps at 30 volts.
5
3
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
.
C
h
e
c
k
o
i
l
l
e
v
e
l
f
r
e
q
u
e
n
t
l
y
d
u
r
-
4
ing run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place V/A control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.
+
Stop engine and let cool.
6
Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
OM-492 Page 50
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SECTION 11 − GENERATOR POWER GUIDELINES
. The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
11-1. Selecting Equipment
1
2
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
. Be sure equipment has double
insulated symbol and/or word-
ing on it.
1
2
!
Do not use 2-prong plug un-
less equipment is double in-
sulated.
3
OR
gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577
11-2. Grounding Generator To Truck Or Trailer Frame
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
Also see AWS Safety
&
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
1
2
3
EquipmentGrounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
1
Metal Vehicle Frame
2
GND/PE
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
. Electrically bond generator
frame to vehicle frame by met-
al-to-metal contact.
3
!
Bed liners, shipping skids,
and some running gear insu-
late the welding generator
from the vehicle frame. Al-
ways connect a ground wire
from the generator equip-
ment grounding terminal to
bare metal on the vehicle
frame as shown.
!
If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.
S-0854
OM-492 Page 51
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11-3. 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
.
U
s
e
g
r
o
u
n
d
d
e
v
i
c
e
a
s
s
t
a
t
e
d
i
n
electrical codes.
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
!
Also see AWS Safety
&
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
2
3
ST-800 576-B
11-4. How Much Power Does Equipment Require?
1
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
Non-Resistive Load
3
VOLTS 115
Equipment with a motor is a non-re-
sistive load and requires approxi-
mately six times more power while
starting the motor than when running
2
AMPS 4.5
Hz
60
1
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
3
Amperes x Volts = Watts
Example 1: If a drill uses 4.5 am-
peres at 115 volts, calculate its run-
ning power requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Ex-
ample 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-492 Page 52
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11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Rating
Starting Watts
Running Watts
Split Phase
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
Capacitor Start-Induction Run
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
1-1/2 HP
2 HP
3 HP
5 HP
Capacitor Start-Capacitor Run
Fan Duty
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
550
650
800
1100
11-6. Approximate Power Requirements For Farm/Home Equipment
Farm/HomeEquipment
Stock Tank De-Icer
Rating
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
Grain Cleaner
1/4 HP
1/2 HP
3/4 HP
Portable Conveyor
Grain Elevator
1000
1400
1100
2800
720
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1-1/2 HP
2 HP
3 HP
5 HP
High Torque (e.g. Barn
1-1/2 HP
5 HP
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
1400
1600
800
Refrigerator or Freezer
Shallow Well Pump
1/3 HP
1/2 HP
1/3 HP
1/2 HP
750
1000
800
Sump Pump
1050
OM-492 Page 53
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11-7. 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-492 Page 54
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11-8. Power Required To Start Motor
Single-PhaseInduction 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
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
4
1
3
AC MOTOR
2
Motor Voltage
VOLTS 230
AMPS 2.5
To find starting amperage:
CODE
HP
M
Hz
60
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiplyrunning amperage by six to
find starting amperage.
1/4
PHASE 1
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amper-
age (see example).
Welding generator amperage out-
put must be at least twice the
motor’s running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amper-
age required for a 230 V, 1/4 HP mo-
tor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624
11-9. 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
OM-492 Page 55
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11-10. Typical Connections To Supply Standby Power
!
!
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
4
1
2
3
Fused
Disconnect
Switch
Properly install and ground
this equipment according to
its Owner’s Manual and na-
tional, state, and local codes.
Welding
Generator
Output
Utility
Electrical
Service
Transfer Switch
(If Required)
. Customer-supplied equipment
is required if generator will sup-
ply standby power during
emergencies or power out-
ages.
5
1 Utility Electrical Service
Essential
Loads
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is re-
stored.
Install correct switch (customer-
supplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customer-
supplied) if required by electrical
code.
4 Welding Generator Output
Generator output voltage and wir-
ing must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low volt-
age and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the prem-
ises. If generator does not produce
enough output to meet all require-
ments, connect only essential
loads (pumps, freezers, heaters,
OM-492 Page 56
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11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
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
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-492 Page 57
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SECTION 12 − PARTS LIST
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
16
not available unless listed.
17
15
14
13
5
6
11
12
10
9
18
8
7
3
2
4
105
1
19
20
21
22
23
27
24
25
26
28
29
104
103
Fig. 12-3
102
101
1000
98
99
97
96
94
94
95
93
Fig. 12-2
90
92
91
Figure 12-1. Main Assembly
OM-492 Page 58
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43
44
45
42
41
40
39
38
46
54
15
37
33
36
35
34
47
48
49
31
32
51
52
55
56
53
50
30 Fig. 12-4
67
71
57
58
59
60
61
68
65
70
66
63
85
86
62
64
69
78
87
72
84
83
73
74
75
76
82
77
79
81
80
89
88
802 324-N
OM-492 Page 59
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
. . 1 . . . . . . . . . . . . +198 157 . . PANEL, generator left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 1 . . . . . . . . . . ♦+198 873 . . PANEL, generator left stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . +198 155 . . COVER, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . +♦198 871 . . COVER, generator stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . ♦163163 . . SCREW, 250−20x .50 Hex Hd−pln Stainless Pln T18−8 302−305 . . . . . . . . 37
. . . . . . . . . . . . . . . . . ♦163175 . . SCREW, 250−20x .75 Hex Hd−pln Stainless Pln T18−8 302−305 . . . . . As Rqd.
. . . . . . . . . . . . . . . . . ♦163167 . . WASHER, Lock .254idx0.489odx.062t Stainless Split.250 . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . ♦163174 . . WASHER, Flat .281idx0.625odx.050t Stainless . . . . . . . . . . . . . . . . . . . . . . . 37
. . 3 . . . . . . . . . . . . . . 233953 . . LABEL, warning general precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . 107 990 . . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . 198 159 . . TRAY, fuel spill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . 200 366 . . EDGE TRIM, style 70−p−11 nitrile rubber x roll . . . . . . . . . . . . . . . . . . . . . . . 2 ft
. . 7 . . . . . . . . . . . . . 193 411 . . BRACE, hood access rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . 198 156 . . DOOR, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . ♦198 872 . . DOOR, access stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . 198 525 . . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 10 . . . . . . . . . . . +198 164 . . HOOD, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . +♦198 878 . . HOOD, access stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . 194 320 . . LATCH, door access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 12 . . . . . . . . . . . . 194 295 . . LABEL, engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . 198 162 . . PLENUM, radiator cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . ♦198 875 . . PLENUM, radiator cover stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . 200 448 . . LABEL, warning steam and hot coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 15 . . . . . . . . . . . . 109 591 . . CLAMP, muffler 1.750dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 16 . . . . . . . . . . . . 201 882 . . PIPE, exhaust elbow 1.654 ID stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . 198 153 . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . . . . . . . . . . . 176 230 . . LABEL, hot exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 19 . . . . . . . . . . . . 198 154 . . DOOR, access removable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 19 . . . . . . . . . . ♦198 870 . . DOOR, access removable stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . 209 344 . . SEAL, lifting eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . 090 281 . . LABEL, caution do not use ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 23 . . . . . . . . . . . . 198 054 . . UPRIGHT, base center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . CR2 . . . . 155 309 . . CONTACTOR, solenoid 12VDC continuous 400 A . . . . . . . . . . . . . . . . . . . . . 1
. . 25 . . . . . . . . . . . . 193 414 . . BRACKET, mtg gas spring front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 26 . . . . . . . . . . . . 172 296 . . BALL GAS SPRING, stud .39dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 27 . . . . . . . . . . . . 192 239 . . SPRING, pressure gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . . . . . . . . 206 795 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 29 . . . . . . . . . . . . 197 265 . . BRACKET, mtg air cleaner and stop door access . . . . . . . . . . . . . . . . . . . . . 1
. . 30 . . . . . . . . . Figure 12-4 . . GENERATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 31 . . . . . . . . . . . . 193 624 . . ENGINE, Kubota dsl elec (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . . S2 . . . . *197 145 . . . . SWITCH, oil pressure 7 psi no screw terminal (included w/engine) . . . . . 1
. . . . . . . . . . . . . . . . . . 114 923 . . BOOT, insulator term post red (for starter and alternator terminals) . . . . . . 2
. . 33 . . . . . . . . . . . . 200 653 . . HEATER, block engine 120v 400w kabota 905 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 34 . . . S3 . . . . . 205 800 . . SWITCH, thermo temp 230deg 5deg F NO . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 35 . . . . . . . . . . . . 192 517 . . GASKET, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 36 . . . . . . . . . . . . 192 194 . . PIPE, exhaust flexible inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 37 . . . . . . . . . . . . 191 693 . . GUARD, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 38 . . . . . . . . . . . +202 243 . . SHROUD, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . 191 341 . . HOSE, radiator outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 40 . . . . . . . . . . . . 198 186 . . BRACKET, mtg radiator LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . 197 822 . . RADIATOR, w/14# cap 3 row core 1.125 inlet/outlet . . . . . . . . . . . . . . . . . . . 1
. . 42 . . . . . . . . . . . . 194 578 . . BAFFLE, air foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 43 . . . . . . . . . . . . 198 181 . . RADIATOR ARCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 44 . . . . . . . . . . . . 191 626 . . BUMPER, door access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 45 . . . . . . . . . . . . 192 195 . . PIPE, exhaust outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 46 . . . . . . . . . . . . 182 092 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 47 . . . . . . . . . . . . 201 528 . . MUFFLER, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 48 . . . . . . . . . . . . 198 187 . . BRACKET, mtg radiator RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 49 . . . . . . . . . . . . 198 185 . . BAFFLE, lower radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 50 . . . . . . . . . . . . 191 342 . . HOSE, radiator inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Figure 12-1. Main Assembly (Continued)
. . 51 . . . . . . . . . . . . 202 198 . . BASE, fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 52 . . . . . . . . . . . *192 744 . . FILTER, fuel spin-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 53 . . . . . . . . . . . . 187 462 . . BOTTLE, overflow w/cap and hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 208 124 . . . . . CAP, w/gasket overflow bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 192 934 . . BRACKET, mtg coolant recovery tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 54 . . . . . . . . . . . . 197 146 . . FAN, engine 330mm pusher kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 55 . . . . . . . . . . . *066 113 . . FILTER, fuel inline .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 56 . . . . . . . . . . . *196 428 . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 57 . . . . . . . . . . . . 192 475 . . SUPPORT, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 58 . . . . . . . . . . . . 192 476 . . MOUNT, engine vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 59 . . . . . . . . . . . . 118 829 . . SCREW, shld stl sch .312-18 x .500 x .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 60 . . . . . . . . . . . . 194 127 . . LINKAGE, throttle solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 61 . . . . . . . . . . . . 145 675 . . NUT, .312-18 x .50 hex .37h stl pld deformed . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 62 . . . . . . . . . . . . 192 196 . . SOLENOID, 12VDC 46A push/hold (throttle) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 63 . . . . . . . . . . . . 192 663 . . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 64 . . . . . . . . . . . . 047 234 . . BOLT, banjo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 65 . . . . . . . . . . . . 047 235 . . WASHER, seal oil copper .879 ID x 1.059 OD . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 66 . . . . . . . . . . . . 203 897 . . HOSE, oil w/fittings 22.500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 67 . . . . . . . . . . . . 165 271 . . VALVE, oil drain 3/8-18 NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 68 . . . . . . . . . . . . 209 329 . . INDICATOR, restriction air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 69 . . . . . . . . . . . . 197 256 . . HOSE, elbow air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 70 . . . . . . . . . . . . 193 026 . . BAND, mtg air cleaner case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 71 . . . . . . . . . . . . 192 188 . . AIR CLEANER, intake 90deg outlet 4.25 in dia . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *187 441 . . ELEMENT, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦202 102 . . ELEMENT, air cleaner safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 72 . . . . . . . . . . . . 197 227 . . HOSE, elbow air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 73 . . . . . . . . . . . . 032 453 . . CABLE, bat neg 24.375 No. 2 awg w/clamp and .375 rng . . . . . . . . . . . . . . 1
. . 74 . . . . . . . . . . . . 204 875 . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 75 . . . . . . . . . . . . 146 237 . . BATTERY, stor 12V 535crk 90rsv gp 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 76 . . . . . . . . . . . . 494 604 . . BOLT, j stl .250−20 x 8.000 pld w/nuts&washers . . . . . . . . . . . . . . . . . . . . . . 2
. . 77 . . . . . . . . . . . . 182 276 . . CABLE, bat pos 28.000 No. 1 awg w/clamp and .406 lug . . . . . . . . . . . . . . . 1
. . 78 . . . . . . . . . . . . 110 465 . . TUBING, corrugated plastic slit .500 dia xcoil . . . . . . . . . . . . . . . . . . . . . . . . 2.1 ft
. . . . . . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 79 . . . . . . . . . . . . . 097829 . . BOLT, J Stl .250−20 X 2.750 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 80 . . . . . . . . . . . . 200 407 . . STRAP, Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 81 . . . . . . . . . . . . 198 168 . . SUPPORT, Fuel Tank/Weld Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 82 . . . . . . . . . . . . 198 180 . . TANK, Fuel 13.1 Gal (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 83 . . . . . . . . . . . . 124 253 . . . . BUSHING, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 84 . . . . . . . . . . . . 198 510 . . . . FTG, Stand Pipe Hose .3125 X24.570lg 90 Deg Zinc . . . . . . . . . . . . . . . . 1
. . 85 . . . . . . . . . . . . 198 511 . . . . FTG, Stand Pipe Hose .1875x24.570lg 90 Deg Zinc . . . . . . . . . . . . . . . . . 1
. . 86 . . . . . . . . . . . . 190 198 . . . . CAP, Tank Screw−on 3.500 In W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 87 . . . . . . . . . . . . 198 512 . . . . SENDER, Fuel Gauge 22.500 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 88 . . . . . . . . . . . . 189 908 . . . . VALVE, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 89 . . . . . . . . . . . . 181 572 . . . . BUSHING, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 90 . . . . . . . . . . . . 197 930 . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 91 . . . . . . . . . . . . 197 835 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 92 . . . . . . . . . . . . 192 477 . . MOUNT, engine vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 93 . . . . . . . . . Figure 12-2 . . FRONT PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 94 . . . . . . . . . . . . 198 167 . . SUPPORT, inverter chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 95 . . . . . . . . . . . . 190 861 . . LABEL, electric shock and moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Figure 12-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . . 213 226 . . HARNESS, wiring ignition (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 96 CR1, CR2 . . 173 069 . . . . RELAY, encl 12VDC SPDT 30A/20A 5 pin flange mtg . . . . . . . . . . . . . . . . 2
. . 97 . . . . . . . . . . . . 197 147 . . . . BLOCK, term 5-4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 98 . . . D3 . . . . . 135 184 . . . . DIODE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 99 . . . . . . . . . . . . 191 735 . . . . STRIP, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG26 . . . 135 275 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug (service kit) . . . . . . . . . . . 1
. . . . . . . . PLG5 . . . . 166 680 . . . . CONNECTOR, rect univ 084 12P/S 3 row plug (service kit) . . . . . . . . . . . 1
. . . . . . . . PLG8 . . . . 177 859 . . . . CONNECTOR, body 5 terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG34 . . . 153 501 . . . . CONNECTOR, rect univ 039 6P/S 3 row plug (service kit) . . . . . . . . . . . . 2
. . . . . . . . . S6 . . . . . 021 467 . . . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 187 654 . . . . SEAL, wire univ 12p/s 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 187 655 . . . . SEAL, wire univ 15p/s 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 208 871 . . HARNESS, wiring engine compartment (consisting of) . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC5 . . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG38 . . . 192 170 . . . . CONNECTOR, rect 250 2skt 1 row plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 192 169 . . . . CONNECTOR, rect 250 1skt 1 row plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG36 . . . 192 171 . . . . CONNECTOR, rect 250 3skt 1 row plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG37 . . . 192 168 . . . . CONNECTOR, rect 250 1 pin 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG39 . . . 092 670 . . . . CONNECTOR, rect univ 084 3P/S 1 row plug . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 192 167 . . . . SEAL, wire univ 3P/S 1 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 100 . . CB7 . . . . 147 658 . . . . CIRCUIT BREAKER, man rest 1P 30A 250VAC screw (see Figure 12-1) 1
. 101 . . CB8 . . . . 115 427 . . . . CIRCUIT BREAKER, man reset 1P 25A 250VAC frict (see Figure 12-1) 1
. 102 . . CB10 . . . . 139 266 . . . . SUPPLEMENTARY PROTECTOR, man reset 1P 15A 250VAC
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (see Figure 12-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 187 654 . . . . SEAL, wire univ 12p/s 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin (for CR3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 103 . . . . . . . . . Figure 12-3 . . INVERTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 104 . . . . . . . . . . . . 198 158 . . PANEL, generator right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 104 . . . . . . . . . . ♦198 874 . . PANEL, generator right stainless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 105 . . . . . . . . . . . . . 233088 . . Label, Danger Using A Generator Indoors Can Kill You In Minutes . . . . . . . 1
. . . . . . . . . . . . . . . . . . 194 126 . . KIT, foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦ Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-492 Page 62
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802 327-F
Figure 12-2. Front Panel
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . 1 . . . . . . . . . . . . . 198 049 . . UPRIGHT, base front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . +191 737 . . PANEL, front louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . 170 391 . . CONN, circ ms protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 RC14, PC6 . 224 951 . . CIRCUIT CARD ASSY, connector/receptacle . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG13 . . . 115 091 . . CONNECTOR, rect mini 045 10skt 2 row plug (service kit) . . . . . . . . . . . . . 1
. . 5 . CB5,CB6 . . 083 432 . . SUPPLEMENTARY PRO, man reset 1P 10A 250VAC frict . . . . . . . . . . . . . 2
. . 6 . . 2T, 3T . . . 172 661 . . BLOCK, stud connection 6 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 7 . . . . . . . . . . . . . 212 480 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . 206 795 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 9 . . . . . . . . . . . . . 601 836 . . NUT, 250-20 .50hex .19H brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . 10 . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . PC10 . . . . 148 608 . . CIRCUIT CARD ASSEMBLY, filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . 134 201 . . STAND−OFF SUPPORT, pc card .312/.375w/post&lock .43 . . . . . . . . . . . . 6
. . 13 . . . . . . . . . . . . . . . . . . . . . . . PLATE, lower (order by model & serial number) . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, upper (order by model & serial number) . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . 083 030 . . STUD, brs .250-20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 17 . . . . . . . . . . . . 213 456 . . COVER, receptacle duplex dual gfci weather proof . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . . . . . . . . . . . 209 056 . . COVER, receptacle w/ gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . . . . . . . . . . . 203 016 . . BOOT, circuit breaker 2 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . 119 014 . . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . 021 385 . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-492 Page 63
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-2. Front Panel (Continued)
. . 22 . . . . . . . . . . . . 192 265 . . GAUGE, fuel elec switch w/o switchgage sensor . . . . . . . . . . . . . . . . . . . . . . 1
. . 23 . . . . . . . . . . . . 145 247 . . METER, hour 12−24vdc 1.25 x 2.12 rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 PL1, PL2, PL3 . 206 879 . . LIGHT, ind amber lens 12v snap−in mtg .500 mtg hol . . . . . . . . . . . . . . . . . . 1
. . 25 . . CT2 . . . . 192 237 . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 26 . . . S6 . . . . . 021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . S1 . . . . . 176 606 . . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . PC3 . . . . 225 974 . . CIRCUIT CARD ASSEMBLY, front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 210 844 . . SHIELD, pcb protective anti static 6.338x11.000 . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . RC1 . . . . 182 954 . . RECEPTACLE, str 3p4w 50a 125/250V (single-phase) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . ♦119 172 . . PLUG, str grd 3p4w 50a 125/250v *14−50p (for RC1) . . . . . . . . . . . . . . . . . . 1
. . 30 . . CB1 . . . . 217 858 . . SUPPLEMENTARY PROTECTOR, man reset 2P 50A 240VAC . . . . . . . . 1
. . 31 RC2, RC3 . . 214 918 . . RECEPTACLE, str dx grd 2p3w 20a 125v *5−20r . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . GFCI-1, 2 ♦151 981 . . RECEPTACLE, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . 2
. . 32 CB2,CB3 . . 093 996 . . SUPPLEMENTARY PRO, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . 2
. . 33 . . RC4 . . . . 007 469 . . RECEPTACLE, twlk grd 3P4W 30A 250V (3-phase) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦007 470 . . PLUG, tw lk grd 3p4w 30a 250v *l15−30p (For RC4) . . . . . . . . . . . . . . . . . . . 1
. . 34 . . CB4 . . . . 192 565 . . SUPPLEMENTARY PROTECTOR, man reset 3P 30A 250VAC . . . . . . . . 1
. . 35 . . . . . . . . . . . . 203 017 . . BOOT, circuit breaker 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 36 . . . . . . . . . . . . 174 991 . . KNOB, pointer 1.250dia x .250 ID w/spring clip . . . . . . . . . . . . . . . . . . . . . . . 2
. . 37 . . . . . . . . . . . . 174 992 . . KNOB, pointer .820dia x .250 ID w/spring clip . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 38 . . PC9 . . . . 181 261 . . CIRCUIT CARD ASSY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 40 . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 41 . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦ Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-492 Page 64
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33
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26
18
39
40
41
28
42
32
25
24
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31
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802 326-B
1
Figure 12-3. Inverter Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . 1 . . . PC2 . . . . 196 148 . . CIRCUIT CARD ASSEMBLY, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . C3,C4,C5 . . 192 935 . . CAPACITOR, elctlt 2700uf 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 3 . . . . C1 . . . . . 186 015 . . CAPACITOR, polyp film .34uf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . 025 248 . . STAND-OFF, insul .250-20 x 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 5 . . . . . . . . . . . . . 179 276 . . BUSHING, snap-in nyl 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . 175 140 . . BRACKET, DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . 181 197 . . GASKET, DI/DT rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . L3,L4 . . . . 175 482 . . COIL, DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . . . . . . . . . . . 109 056 . . CORE, ferrite E 2.164 lg x 1.09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 10 . . . . . . . . . . . . 185 731 . . WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . 189 755 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . 191 568 . . FOOT, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 13 . . . . . . . . . . . . 200 649 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . 170 647 . . BUSHING, snap-in 1.312 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 15 . . . . . . . . . . . . 175 084 . . MOTOR, fan 24VDC 3000RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . SR1 . . . . 179 629 . . KIT, diode power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 PM1,PM2 . . 180 110 . . KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 18 RT1,RT2 . . 173 632 . . THERMISTOR, NTC 30K ohm at 25D C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . . . . . . . . . . . 173 631 . . HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . 175 192 . . HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . 175 255 . . INSULATOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . . . . . . . +183 551 . . WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-492 Page 65
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-3. Inverter Assembly (Continued)
. . 23 . . . . . . . . . . . . 181 853 . . INSULATOR, screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 24 . . HD1 . . . . 189 567 . . TRANSDUCER, current 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 25 . D1,D2 . . . 179 630 . . KIT, diode ultra-fast recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 26 R1,C6,C7 . . 175 194 . . RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . . . . . . . . . . 185 835 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 28 . . . T1 . . . . . 173 811 . . TRANSFORMER, HF 230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . L1 . . . . . 173 563 . . INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 30 . . . Z1 . . . . . 189 525 . . STABILIZER, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 31 . . . . . . . . . . . . 189 420 . . BRACKET, mtg capacitor/PC board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . PC1 . . . . 212 691 . . CIRCUIT CARD ASSEMBLY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . . . . . . . . . +213 412 . . WRAPPER, inverter chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 34 . . . . . . . . . . . . 190 861 . . LABEL, electric shock and moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 35 . . . . . . . . . . . . 200 590 . . COVER, ribbon access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 36 . . . T2 . . . . . 189 481 . . TRANSFORMER, control 300VA 230VAC pri . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 37 . . . . . . . . . . . . 172 731 . . HOLDER, fuse mintr .250 x 1.250 clip anti−pivot . . . . . . . . . . . . . . . . . . . . . . 1
. . 38 . . . F1 . . . . . 169 296 . . FUSE, mintr gl 25. amp 125 volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . 189 422 . . BRACKET, mtg transformer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 40 . . SR2 . . . . 035 704 . . RECTIFIER, integ bridge 40. amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . 115 440 . . STAND-OFF, No. 6-32 x .687 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . 42 . . . . . . . . . . . . 200 651 . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 43 . . PC8 . . . . 213 231 . . CIRCUIT CARD ASSEMBLY, voltage regulator . . . . . . . . . . . . . . . . . . . . . . . 1
. . 44 . . PC7 . . . . 203 130 . . CIRCUIT CARD ASSY, gen power (includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . F1 . . . . . . 027660 . . . . FUSE, Mintr Cer 20. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 45 . . . . . . . . . . . . 153 403 . . BUSHING, snap-in nyl .750 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 46 . . . . . . . . . . . . 177 547 . . BUSHING, snap-in nyl ct-mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 47 . . CT1 . . . . 175 199 . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 213 410 . . HARNESS, wiring unit (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC26 . . . . 147 663 . . . . CONNECTOR, rect univ 084 15 p/s 3 row rectp lkg (service kit) . . . . . . . 1
. . . . . . . . RC25 . . . . 116 045 . . . . CONNECTOR, rect univ 084 6p/s 3 row rcpt lkg (service kit) . . . . . . . . . . 1
. . . PLG24, PLG44 115 094 . . . . CONNECTOR, rect mini 045 4skt 2 row plug (service kit) . . . . . . . . . . . . . 1
. . . . RC10, PLG31 168 071 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt (service kit) . . . . . . . . . . . . 1
. . . . . . . . PLG2 . . . . 115 091 . . . . CONNECTOR, rect mini 045 10skt 2 row plug (service kit) . . . . . . . . . . . . 1
. . . . . . . PLG23 . . . 130 203 . . . . CONNECTOR, rect mini 045 12 skt 2 row plug (service kit) . . . . . . . . . . . 1
. . . . . . . . RC24 . . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt (service kit) . . . . . . . . . . . 1
. . . . . . . PLG50 . . . 136 810 . . . . CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg (service kit) . . . . 1
. . . . . . . PLG43 . . . 115 093 . . . . CONNECTOR, rect mini 045 6skit 2row plg cable lkg (service kit) . . . . . . 1
. . . . . . . PLG21 . . . 115 092 . . . . CONNECTOR, rect mini 045 8skt 2row plug cable lkg (service kit) . . . . . 1
. . . . . . . PLG22 . . . 131 204 . . . . CONNECTOR, rect mini 045 3skt 1row plug cable lkg (service kit) . . . . . 1
. . . . . . . . PLG9 . . . . 183 046 . . . . CABLE, LEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*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-492 Page 66
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.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.
8
7
6
3
5
4
1
9
2
10
11
802 338-B
Figure 12-4. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . 1 . . . . . . . . . . . . . 217 046 . . ENDBELL (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . 216 532 . . . . RING, tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . 213 388 . . ROTOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . 181 143 . . . . BEARING, ball rdl sgl row .984 x 2.047 x .591 . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . 192 600 . . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . +212 957 . . STATOR, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . 159 918 . . BAFFLE, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . 193 515 . . ADAPTER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 10 . . . . . . . . . . . . 170 861 . . STUD, stl .375-16 x 17.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 11 . . . . . . . . . . . . 205 725 . . BRUSHHOLDER ASSY, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*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-492 Page 67
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Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
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Notes
Invision 354MP
TM-188 304 Page 2
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Notes
Start Your Professional
Welding Career Now!
Over 80,000 trained
since 1930!
400 Trade Square East, Troy, Ohio 45373
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Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
*
Accessory (Kits)
Replacement Parts (No labor)
Spoolmate Spoolguns
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:
Service
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
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 delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
Original main power rectifiers
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
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.
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.
3. 1 Year — Parts and Labor Unless Specified
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
*
*
*
*
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.
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
Grids
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
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
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.
*
(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.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
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.
*
*
*
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,
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
but may vary from province to province.
miller_warr 2007−01
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
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
To locate a Distributor or Service Agency visit
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2007 Miller Electric Mfg. Co.2007−01
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