OM-4435 218 759AL

2012−11
Processes
Stick (SMAW) Welding

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

Description

Engine Driven Welding Generator

Big Blue 400 CX CE

)

File: Engine Drive

Visit our website at
www.MillerWelds.com
 From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard. particular model are also provided.

Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 2009−09
 TABLE OF CONTENTS

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

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 11
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-8. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-3. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-4. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-7. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-8. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-2. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-4. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-5. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-6. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-7. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-10. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-4. Lift-Arc TIG With Crater-Out And Auto-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-6. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-7. Optional Engine Block Heater Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
 TABLE OF CONTENTS

SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7-1. Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-2. GFCI Receptacle Information, Resetting And Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-3. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-5. Inspecting And Cleaning Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-6. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-7. Adjusting Engine Speed On Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8-8. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8-9. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8-10. Optional Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DECLARATION OF CONFORMITY
for European Community (CE marked) products.

MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:
Product Stock Number
Big Blue 400CX CC 907143

Council Directives:
• 2006/95/EC Low Voltage
• 2004/108/EC Electromagnetic Compatibility
• 2000/14/EC Noise Level of Welding Generators

Standards:
• IEC 60974­1:2005 Arc welding equipment – Part 1: Welding power sources
• IEC 60974­10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
• EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,
arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic
fields (0 Hz – 300Hz)

Signatory:

November 29, 2010

_____________________________________ ___________________________________________
David A. Werba Date of Declaration

MANAGER, PRODUCT DESIGN COMPLIANCE

245808­B
 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2011−10

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

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

1-2. Arc Welding Hazards

 Always verify the supply ground — check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you
disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions
grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information  When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-7. Read and tor first − double-check connections.
follow all Safety Standards.  Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and  Frequently inspect input power cord for damage or bare wiring —
repair this unit. replace cord immediately if damaged — bare wiring can kill.
 Turn off all equipment when not in use.
During operation, keep everybody, especially children, away.  Do not use worn, damaged, undersized, or poorly spliced cables.
 Do not drape cables over your body.
ELECTRIC SHOCK can kill.  If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Touching live electrical parts can cause fatal shocks or  Do not touch electrode if you are in contact with the work, ground,
severe burns. The electrode and work circuit is or another electrode from a different machine.
electrically live whenever the output is on. The input  Use only well-maintained equipment. Repair or replace damaged
power circuit and machine internal circuits are also live parts at once. Maintain unit according to manual.
when power is on. In semiautomatic or automatic wire
 Do not touch electrode holders connected to two welding ma-
welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically chines at the same time since double open-circuit voltage will be
live. Incorrectly installed or improperly grounded present.
equipment is a hazard.  Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Do not touch live electrical parts.  Clamp work cable with good metal-to-metal contact to workpiece
 Wear dry, hole-free insulating gloves and body protection. or worktable as near the weld as practical.
 Insulate work clamp when not connected to workpiece to prevent
 Insulate yourself from work and ground using dry insulating mats contact with any metal object.
or covers big enough to prevent any physical contact with the work  Do not connect more than one electrode or work cable to any
or ground. single weld output terminal. Disconnect cable for process not in
 Do not use AC output in damp areas, if movement is confined, or if use.
there is a danger of falling. SIGNIFICANT DC VOLTAGE exists in inverter power
 Use AC output ONLY if required for the welding process. sources AFTER stopping engine.
 If AC output is required, use remote output control if present on  Stop engine on inverter and discharge input capacitors according
unit. to instructions in Maintenance Section before touching any parts.

 Additional safety precautions are required when any of the follow- HOT PARTS can burn.
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such  Do not touch hot parts bare handed.
as floors, gratings, or scaffolds; when in cramped positions such
 Allow cooling period before working on equip-
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
ment.
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a  To handle hot parts, use proper tools and/or wear heavy, insu-
semiautomatic DC constant voltage (wire) welder, 2) a DC manual lated welding gloves and clothing to prevent burns.
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder FLYING METAL or DIRT can injure eyes.
is recommended. And, do not work alone!
 Disconnect input power or stop engine before installing or  Welding, chipping, wire brushing, and grinding
servicing this equipment. Lockout/tagout input power according to cause sparks and flying metal. As welds cool,
OSHA 29 CFR 1910.147 (see Safety Standards). they can throw off slag.
 Properly install, ground, and operate this equipment according to  Wear approved safety glasses with side shields even under your
its Owner’s Manual and national, state, and local codes. welding helmet.

OM-4435 Page 1
  Do not weld on containers that have held combustibles, or on
FUMES AND GASES can be hazardous. closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Welding produces fumes and gases. Breathing these Safety Standards).
fumes and gases can be hazardous to your health.  Do not weld where the atmosphere may contain flammable dust,
 Keep your head out of the fumes. Do not breathe the fumes. gas, or liquid vapors (such as gasoline).
 If inside, ventilate the area and/or use local forced ventilation at the  Connect work cable to the work as close to the welding area as
arc to remove welding fumes and gases. practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire haz-
 If ventilation is poor, wear an approved air-supplied respirator. ards.
 Read and understand the Material Safety Data Sheets (MSDSs)
 Do not use welder to thaw frozen pipes.
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.  Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
 Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-  Wear oil-free protective garments such as leather gloves, heavy
person nearby. Welding fumes and gases can displace air and shirt, cuffless trousers, high shoes, and a cap.
lower the oxygen level causing injury or death. Be sure the breath-  Remove any combustibles, such as a butane lighter or matches,
ing air is safe. from your person before doing any welding.
 Do not weld in locations near degreasing, cleaning, or spraying op-  After completion of work, inspect area to ensure it is free of sparks,
erations. The heat and rays of the arc can react with vapors to form glowing embers, and flames.
highly toxic and irritating gases.
 Use only correct fuses or circuit breakers. Do not oversize or by-
 Do not weld on coated metals, such as galvanized, lead, or pass them.
cadmium plated steel, unless the coating is removed from the weld
 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
area, the area is well ventilated, and while wearing an air-supplied
for hot work and have a fire watcher and extinguisher nearby.
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
NOISE can damage hearing.
BUILDUP OF GAS can injure or kill. Noise from some processes or equipment can dam-
age hearing.
 Shut off compressed gas supply when not in use.
 Always ventilate confined spaces or use ap-  Wear approved ear protection if noise level is
proved air-supplied respirator. high.
ELECTRIC AND MAGNETIC FIELDS (EMF)
ARC RAYS can burn eyes and skin. can affect Implanted Medical Devices.

Arc rays from the welding process produce intense  Wearers of Pacemakers and other Implanted
visible and invisible (ultraviolet and infrared) rays that Medical Devices should keep away.
can burn eyes and skin. Sparks fly off from the weld.  Implanted Medical Device wearers should consult their doctor
 Wear an approved welding helmet fitted with a proper shade of filter and the device manufacturer before going near arc welding, spot
lenses to protect your face and eyes from arc rays and sparks welding, gouging, plasma arc cutting, or induction heating
when welding or watching (see ANSI Z49.1 and Z87.1 listed in operations.
Safety Standards).
CYLINDERS can explode if damaged.
 Wear approved safety glasses with side shields under your
helmet.
Compressed gas cylinders contain gas under high
 Use protective screens or barriers to protect others from flash, pressure. If damaged, a cylinder can explode. Since
glare, and sparks; warn others not to watch the arc. gas cylinders are normally part of the welding process,
 Wear protective clothing made from durable, flame-resistant mate- be sure to treat them carefully.
rial (leather, heavy cotton, or wool) and foot protection.  Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
WELDING can cause fire or explosion.  Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Welding on closed containers, such as tanks, drums,  Keep cylinders away from any welding or other electrical circuits.
or pipes, can cause them to blow up. Sparks can fly off  Never drape a welding torch over a gas cylinder.
from the welding arc. The flying sparks, hot workpiece,
and hot equipment can cause fires and burns. Accidental contact of  Never allow a welding electrode to touch any cylinder.
electrode to metal objects can cause sparks, explosion, overheating,  Never weld on a pressurized cylinder — explosion will result.
or fire. Check and be sure the area is safe before doing any welding.  Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
 Remove all flammables within 35 ft (10.7 m) of the welding arc. If
and associated parts in good condition.
this is not possible, tightly cover them with approved covers.
 Turn face away from valve outlet when opening cylinder valve.
 Do not weld where flying sparks can strike flammable material.
 Keep protective cap in place over valve except when cylinder is in
 Protect yourself and others from flying sparks and hot metal.
use or connected for use.
 Be alert that welding sparks and hot materials from welding can  Use the right equipment, correct procedures, and sufficient num-
easily go through small cracks and openings to adjacent areas. ber of persons to lift and move cylinders.
 Watch for fire, and keep a fire extinguisher nearby.  Read and follow instructions on compressed gas cylinders,
 Be aware that welding on a ceiling, floor, bulkhead, or partition can associated equipment, and Compressed Gas Association (CGA)
cause fire on the hidden side. publication P-1 listed in Safety Standards.

OM-4435 Page 2
1-3. Engine Hazards
BATTERY EXPLOSION can injure. EXHAUST SPARKS can cause fire.
 Always wear a face shield, rubber gloves, and  Do not let engine exhaust sparks cause fire.
protective clothing when working on a battery.  Use approved engine exhaust spark arrestor in
 Stop engine before disconnecting or connect- required areas — see applicable codes.
ing battery cables, battery charging cables (if
applicable), or servicing battery. HOT PARTS can burn.
 Do not allow tools to cause sparks when working on a battery.
 Do not use welder to charge batteries or jump start vehicles un-  Do not touch hot parts bare handed.
less the unit has a battery charging feature designed for this pur-  Allow cooling period before working on equip-
pose. ment.
 Observe correct polarity (+ and −) on batteries.  To handle hot parts, use proper tools and/or
 Disconnect negative (−) cable first and connect it last. wear heavy, insulated welding gloves and
clothing to prevent burns.
 Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged. STEAM AND HOT COOLANT can burn.
 Follow battery manufacturer’s instructions when working on or
 If possible, check coolant level when engine is
near a battery.
cold to avoid scalding.
 Always check coolant level at overflow tank, if
FUEL can cause fire or explosion. present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
 Stop engine and let it cool off before checking or manual).
adding fuel.  If the engine is warm, checking is needed, and there is no over-
 Do not add fuel while smoking or if unit is near flow tank, follow the next two statements.
any sparks or open flames.  Wear safety glasses and gloves and put a rag over radiator cap.
 Do not overfill tank — allow room for fuel to expand.  Turn cap slightly and let pressure escape slowly before
 Do not spill fuel. If fuel is spilled, clean up before starting engine. completely removing cap.
 Dispose of rags in a fireproof container.
 Always keep nozzle in contact with tank when fueling.
Using a generator indoors CAN KILL
YOU IN MINUTES.
MOVING PARTS can injure.  Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
 Keep away from moving parts such as fans,
 NEVER use inside a home or garage, EVEN IF
belts, and rotors.
doors and windows are open.
 Keep all doors, panels, covers, and guards
closed and securely in place.  Only use OUTSIDE and far away from windows, doors, and
vents.
 Stop engine before installing or connecting unit.
 Have only qualified persons remove doors, panels, covers, or BATTERY ACID can BURN SKIN and EYES.
guards for maintenance and troubleshooting as necessary.
 To prevent accidental starting during servicing, disconnect  Do not tip battery.
negative (−) battery cable from battery.  Replace damaged battery.
 Keep hands, hair, loose clothing, and tools away from moving  Flush eyes and skin immediately with water.
parts.
 Reinstall doors, panels, covers, or guards when servicing is ENGINE HEAT can cause fire.
finished and before starting engine.
 Before working on generator, remove spark plugs or injectors to  Do not locate unit on, over, or near combustible
keep engine from kicking back or starting. surfaces or flammables.
 Block flywheel so that it will not turn while working on generator  Keep exhaust and exhaust pipes way from
components. flammables.

1-4. Compressed Air Hazards

COMPRESSED AIR EQUIPMENT can  Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s in-
injure or kill. structions.
 Incorrect installation or operation of this unit  Do not modify or alter compressor or manufacturer-supplied
could result in equipment failure and personal equipment. Do not disconnect, disable, or override any safety
injury. Only qualified persons should install, op- equipment in the compressed air system.
erate, and service this unit according to its  Use only components and accessories approved by the manufac-
Owner’s Manual, industry standards, and na- turer.
tional, state, and local codes.  Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
 Do not exceed the rated output or capacity of the compressor or
any equipment in the compressed air system. Design compressed  Do not work under or around any equipment that is supported only
air system so failure of any component will not put people or prop- by air pressure. Properly support equipment by mechanical
means.
erty at risk.
 Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
OM-4435 Page 3
 HOT METAL from air arc cutting and MOVING PARTS can injure.
gouging can cause fire or explosion.
 Keep away from moving parts such as fans,
 Do not cut or gouge near flammables. belts and rotors.
 Watch for fire; keep extinguisher nearby.  Keep all doors, panels, covers, and guards
closed and securely in place.
 Keep hands, hair, loose clothing, and tools away from moving
COMPRESSED AIR can injure or kill. parts.
 Before working on compressed air system, turn off and lockout/
 Before working on compressed air system,
tagout unit, release pressure, and be sure air pressure cannot be
turn off and lockout/tagout unit, release pres-
accidentally applied.
sure, and be sure air pressure cannot be acci-
dentally applied.  Have only qualified people remove guards or covers for maint-
 Relieve pressure before disconnecting or con- enance and troubleshooting as necessary.
necting air lines.  Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
 Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
 Do not direct air stream toward self or others.
 Wear protective equipment such as safety glasses, hearing pro-
tection, leather gloves, heavy shirt and trousers, high shoes, and HOT PARTS can burn.
a cap when working on compressed air system.
 Do not touch hot compressor or air system
 Use soapy water or an ultrasonic detector to search for parts.
leaks−−never use bare hands. Do not use equipment if leaks are
 Allow cooling period before working on equip-
found.
ment.
 Reinstall doors, panels, covers, or guards when servicing is
 To handle hot parts, use proper tools and/or wear heavy, insu-
finished and before starting unit.
lated welding gloves and clothing to prevent burns.
 If ANY air is injected into the skin or body seek medical help im-
mediately.

BREATHING COMPRESSED AIR can in-

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

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

FIRE OR EXPLOSION hazard. OVERHEATING can damage motors.

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

OM-4435 Page 4
 BATTERY CHARGING OUTPUT and BATTERY STATIC (ESD) can damage PC boards.
EXPLOSION can injure.
 Put on grounded wrist strap BEFORE handling
Battery charging not present on all models. boards or parts.
 Use proper static-proof bags and boxes to
 Always wear a face shield, rubber gloves, and protective store, move, or ship PC boards.
clothing when working on a battery.
 Stop engine before disconnecting or connecting battery cables,
battery charging cables (if applicable), or servicing battery. TILTING OF TRAILER can injure.
 Do not allow tools to cause sparks when working on a battery.  Use tongue jack or blocks to support weight.
 Do not use welder to charge batteries or jump start vehicles un-  Properly install welding generator onto trailer
less it has a battery charging feature designed for this purpose. according to instructions supplied with trailer.
 Observe correct polarity (+ and −) on batteries.
 Disconnect negative (−) cable first and connect it last.
 Keep sparks, flames, cigarettes, and other ignition sources READ INSTRUCTIONS.
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.  Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
 Follow battery manufacturer’s instructions when working on or servicing unit. Read the safety information at
near a battery. the beginning of the manual and in each
 Have only qualified persons do battery charging work. section.
 If battery is being removed from a vehicle for charging, discon-  Use only genuine replacement parts from the manufacturer.
nect negative (−) cable first and connect it last. To prevent an arc,  Perform maintenance and service according to the Owner’s
make sure all accessories are off. Manuals, industry standards, and national, state, and local
 Charge lead-acid batteries only. Do not use battery charger to codes.
supply power to an extra-low-voltage electrical system or to
charge dry cell batteries. H.F. RADIATION can cause interference.
 Do not charge a frozen battery.
 High-frequency (H.F.) can interfere with radio
 Do not use damaged charging cables.
navigation, safety services, computers, and
 Do not charge batteries in a closed area or where ventilation is communications equipment.
restricted.
 Have only qualified persons familiar with
 Do not charge a battery that has loose terminals or one showing electronic equipment perform this installation.
damage such as a cracked case or cover.
 The user is responsible for having a qualified electrician
 Before charging battery, select correct charger voltage to match promptly correct any interference problem resulting from the
battery voltage. installation.
 Set battery charging controls to the Off position before connect-  If notified by the FCC about interference, stop using the
ing to battery. Do not allow battery charging clips to touch each equipment at once.
other.
 Have the installation regularly checked and maintained.
 Keep charging cables away from vehicle hood, door, or moving
 Keep high-frequency source doors and panels tightly shut, keep
parts.
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

ARC WELDING can cause interference.

WELDING WIRE can injure.  Electromagnetic energy can interfere with
sensitive electronic equipment such as micro-
 Do not press gun trigger until instructed to do processors, computers, and computer-driven
so. equipment such as robots.
 Do not point gun toward any part of the body,  Be sure all equipment in the welding area is
other people, or any metal when threading electromagnetically compatible.
welding wire.  To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
 Locate welding operation 100 meters from any sensitive elec-
OVERUSE can cause OVERHEATING. tronic equipment.
 Be sure this welding machine is installed and grounded
 Allow cooling period; follow rated duty cycle.
according to this manual.
 Reduce current or reduce duty cycle before
 If interference still occurs, the user must take extra measures
starting to weld again.
such as moving the welding machine, using shielded cables,
 Do not block or filter airflow to unit. using line filters, or shielding the work area.

OM-4435 Page 5
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 Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other Diesel engine exhaust and some of its constituents are
reproductive harm. Wash hands after handling. known to the State of California to cause cancer, birth
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
is available as a free download from the American Welding Society at www.csa-international.org).
http://www.aws.org or purchased from Global Engineering Documents
Safe Practice For Occupational And Educational Eye And Face Protec-
(phone: 1-877-413-5184, website: www.global.ihs.com).
tion, ANSI Standard Z87.1, from American National Standards Institute,
Safe Practices for the Preparation of Containers and Piping for Welding 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
and Cutting, American Welding Society Standard AWS F4.1, from Glob- site: www.ansi.org).
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Safe Practices for Welding and Cutting Containers that have Held Com-
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.)
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
www.nfpa.org and www. sparky.org). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
www.osha.gov).
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, Portable Generators Safety Alert, U.S. Consumer Product Safety Com-
website:www.cganet.com). mission (CPSC), 4330 East West Highway, Bethesda, MD 20814
Safety in Welding, Cutting, and Allied Processes, CSA Standard (phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/port-
W117.2, from Canadian Standards Association, Standards Sales, 5060 gen.pdf).
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: Applications Manual for the Revised NIOSH Lifting Equation, The Na-
800-463-6727, website: www.csa-international.org). tional Institute for Occupational Safety and Health (NIOSH), 1600
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
Standards Association, Standards Sales, 5060 Spectrum Way, Suite www.cdc.gov/NIOSH).

1-8. EMF Information

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

OM-4435 Page 6
 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
fre_rom_2011−10

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Signification des symboles

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

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

à souder manuel (électrode enrobée) DC, 3) un poste à souder
Les symboles présentés ci-après sont utilisés tout au long du manuel AC avec tension à vide réduite. Dans la plupart des cas, un
présent manuel pour attirer votre attention et identifier les ris- poste courant continu de type CV est recommandé. Et, ne pas tra-
ques de danger. Lorsque vous voyez un symbole, soyez vailler seul!
vigilant et suivez les directives mentionnées afin d’éviter tout
 Couper l’alimentation ou arrêter le moteur avant de procéder à
danger. Les consignes de sécurité présentées ci-après ne
l’installation, à la réparation ou à l’entretien de l’appareil.
font que résumer l’information contenue dans les normes de
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
sécurité énumérées à la section 1-7. Veuillez lire et respecter
1910.147 (voir normes de sécurité).
toutes ces normes de sécurité.
 Installez, mettez à la terre et utilisez correctement cet équipement
L’installation, l’utilisation, l’entretien et les réparations ne conformément à son Manuel d’Utilisation et aux réglementations
doivent être confiés qu’à des personnes qualifiées. nationales, gouvernementales et locales.
 Installer et mettre à la terre correctement cet appareil conformé-
Au cours de l’utilisation, tenir toute personne à l’écart et plus ment à son manuel d’utilisation et aux codes nationaux,
particulièrement les enfants. 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
UN CHOC ÉLECTRIQUE peut tuer. raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
Un simple contact avec des pièces électriques peut  En effectuant les raccordements d’entrée fixer d’abord le conduc-
provoquer une électrocution ou des blessures gra- teur de mise à la terre approprié et contre-vérifier les connexions.
ves. L’électrode et le circuit de soudage sont sous  Les câbles doivent être exempts d’humidité, d’huile et de graisse;
tension dès que l’appareil est sur ON. Le circuit protégez−les contre les étincelles et les pièces métalliques chau-
d’entrée et les circuits internes de l’appareil sont des.
également sous tension à ce moment-là. En soudage  Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est
semi-automatique ou automatique, le fil, le dévidoir, le pas endommagé ou dénudé − remplacer le cordon immédiatement
logement des galets d’entraînement et les pièces s’il est endommagé − un câble dénudé peut provoquer une électro-
métalliques en contact avec le fil de soudage sont cution.
sous tension. Des matériels mal installés ou mal mis  Mettre l’appareil hors tension quand on ne l’utilise pas.
à la terre présentent un danger.  Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
 Ne jamais toucher les pièces électriques sous tension.
 Ne pas enrouler les câbles autour du corps.
 Porter des gants et des vêtements de protection secs ne compor-  Si la pièce soudée doit être mise à la terre, le faire directement
tant pas de trous. avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
 S’isoler de la pièce et de la terre au moyen de tapis ou d’autres câble de retour.
moyens isolants suffisamment grands pour empêcher le contact  Ne pas toucher l’électrode quand on est en contact avec la pièce,
physique éventuel avec la pièce ou la terre. la terre ou une électrode provenant d’une autre machine.
 Ne pas se servir de source électrique à courant électrique dans les  Ne pas toucher des porte électrodes connectés à deux machines
zones humides, dans les endroits confinés ou là où on risque de en même temps à cause de la présence d’une tension à vide dou-
tomber. blée.
 Se servir d’une source électrique à courant électrique UNIQUE-  N’utiliser qu’un matériel en bon état. Réparer ou remplacer
MENT si le procédé de soudage le demande. sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
 Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil  Porter un harnais de sécurité quand on travaille en hauteur.
en est équipé.  Maintenir solidement en place tous les panneaux et capots.
 Fixer le câble de retour de façon à obtenir un bon contact métal-
 Des précautions de sécurité supplémentaires sont requises dans
métal avec la pièce à souder ou la table de travail, le plus près pos-
des environnements à risque comme: les endroits humides ou
sible de la soudure.
lorsque l’on porte des vêtements mouillés; sur des structures mé-
talliques au sol, grillages et échafaudages; dans des positions  Isoler la pince de masse quand pas mis à la pièce pour éviter le
assises, à genoux et allongées; ou quand il y a un risque important contact avec tout objet métallique.
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser  Ne pas raccorder plus d’une électrode ou plus d’un câble de
les appareils suivants dans l’ordre de préférence: 1) un poste à masse à une même borne de sortie de soudage. Débrancher le
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste câble pour le procédé non utilisé.
OM-4435 Page 7
Il reste une TENSION DC NON NÉGLIGEABLE dans les
sources de soudage onduleur UNE FOIS le moteur coupé.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
 Couper l’alimentation du poste et décharger les condensateurs yeux et sur la peau.
d’entrée comme indiqué dans la Section Maintenance avant de
toucher des composants. Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
LES PIÈCES CHAUDES peuvent (ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
provoquer des brûlures.
soudage.
 Ne pas toucher à mains nues les parties chau-  Porter un casque de soudage approuvé muni de verres filtrants
des. approprié pour protéger visage et yeux pour protéger votre visage
 Prévoir une période de refroidissement avant et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
de travailler à l’équipement. et Z87.1 énuméré dans les normes de sécurité).
 Ne pas toucher aux pièces chaudes, utiliser les outils recomman-  Porter des lunettes de sécurité avec écrans latéraux même sous
dés et porter des gants de soudage et des vêtements épais pour votre casque.
éviter les brûlures.  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.
 Porter des vêtements confectionnés avec des matières résistan-
DES PIECES DE METAL ou DES tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
SALETES peuvent provoquer protection.
des blessures dans les yeux. LE SOUDAGE peut provoquer un
incendie ou une explosion.
 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 Le soudage effectué sur des conteneurs fermés tels
métalliques volantes. Pendant la période de refroidissement des que des réservoirs, tambours ou des conduites peut
soudures, elles risquent de projeter du laitier. provoquer leur éclatement. Des étincelles peuvent
 Porter des lunettes de sécurité avec écrans latéraux ou un écran être projetées de l’arc de soudure. La projection d’étincelles, des
facial. pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
LES FUMÉES ET LES GAZ peu- vérifier et s’assurer que l’endroit ne présente pas de danger.
vent être dangereux.
 Déplacer toutes les substances inflammables à une distance de
Le soudage génère des fumées et des gaz. Leur 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
inhalation peut être dangereux pour votre santé. soigneusement avec des protections homologués.
 Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
 Eloigner votre tête des fumées. Ne pas respirer les fumées.
 Se protéger et d’autres personnes de la projection d’étincelles et
 À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au de métal chaud.
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.  Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
 Si la ventilation est médiocre, porter un respirateur anti-vapeurs
fissures et des ouvertures.
approuvé.
 Surveiller tout déclenchement d’incendie et tenir un extincteur à
 Lire et comprendre les spécifications de sécurité des matériaux proximité.
(MSDS) et les instructions du fabricant concernant les métaux, les  Le soudage effectué sur un plafond, plancher, paroi ou séparation
consommables, les revêtements, les nettoyants et les dégraisseurs. peut déclencher un incendie de l’autre côté.
 Travailler dans un espace fermé seulement s’il est bien ventilé ou  Ne pas effectuer le soudage sur des conteneurs fermés tels que
en portant un respirateur à alimentation d’air. Demander toujours à des réservoirs, tambours, ou conduites, à moins qu ils n aient
un surveillant dûment formé de se tenir à proximité. Des fumées et été préparés correctement conformément à AWS F4.1 et AWS
des gaz de soudage peuvent déplacer l’air et abaisser le niveau A6.0 (voir les Normes de Sécurité).
d’oxygène provoquant des blessures ou des accidents mortels.  Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
S’assurer que l’air de respiration ne présente aucun danger. peurs inflammables (vapeur d’essence, par exemple).
 Ne pas souder dans des endroits situés à proximité d’opérations  Brancher le câble de masse sur la pièce le plus près possible de la
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et zone de soudage pour éviter le transport du courant sur une
les rayons de l’arc peuvent réagir en présence de vapeurs et for- longue distance par des chemins inconnus éventuels en provo-
mer des gaz hautement toxiques et irritants. quant des risques d’électrocution, d’étincelles et d’incendie.
 Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
 Ne pas souder des métaux munis d’un revêtement, tels que l’acier lées.
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
 En cas de non utilisation, enlever la baguette d’électrode du porte-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
électrode ou couper le fil à la pointe de contact.
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent  Porter des vêtements de protection dépourvus d’huile tels que des
dégager des fumées toxiques en cas de soudage. gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
LES ACCUMULATIONS DE GAZ  Avant de souder, retirer toute substance combustible de vos po-
ches telles qu’un allumeur au butane ou des allumettes.
risquent de provoquer des blessures
ou même la mort.  Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-
ce d’étincelles incandescentes ni de flammes.
 Fermer l’alimentation du gaz comprimé en cas  Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
de non utilisation. Ne pas augmenter leur puissance; ne pas les ponter.
 Veiller toujours à bien aérer les espaces confinés ou se servir  Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
d’un respirateur d’adduction d’air homologué. NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
OM-4435 Page 8
  Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
LE BRUIT peut affecter l’ouïe. des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
Le bruit des processus et des équipements peut
affecter l’ouïe.  Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
 Porter des protections approuvés pour les de se renverser.
oreilles si le niveau sonore est trop élevé.  Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants mé-  Ne jamais placer une torche de soudage sur une bouteille à gaz.
dicaux.  Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
 Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à  Ne jamais souder une bouteille pressurisée − risque d’explosion.
distance.
 Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
 Les porteurs d’implants médicaux doivent consulter leur tuyaux et raccords convenables pour cette application spécifique;
médecin et le fabricant du dispositif avant de s’approcher de la les maintenir ainsi que les éléments associés en bon état.
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage  Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
par induction. bouteille.
 Maintenir le chapeau de protection sur la soupape, sauf en cas
Si des BOUTEILLES sont endomma- d’utilisation ou de branchement de la bouteille.
gées, elles pourront exploser.
 Utiliser les équipements corrects, les bonnes procédures et suffi-
Des bouteilles de gaz comprimé protecteur contien- samment de personnes pour soulever et déplacer les bouteilles.
nent du gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les bouteilles de gaz font  Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
normalement partie du procédé de soudage, les manipuler avec
Gas Association) mentionné dans les principales normes de sécu-
précaution.
rité.

2-3. Dangers existant en relation avec le moteur

L’EXPLOSION DE LA BATTERIE Les PIÈCES MOBILES peuvent causer

peut provoquer des blessures. des blessures.
 Toujours porter une protection faciale, des  S’abstenir de toucher des parties mobiles telles
gants en caoutchouc et vêtements de protec- que des ventilateurs, courroies et rotors.
tion lors d’une intervention sur la batterie.
 Maintenir fermés et verrouillés les portes, panneaux,
 Arrêter le moteur avant de débrancher ou de brancher des câbles recouvrements et dispositifs de protection.
de batterie, des câbles de chargeur de batterie (le cas échéant) ou  Arrêter le moteur avant d’installer ou brancher l’appareil.
de batterie d’entretien.
 Lorsque cela est nécessaire pour des travaux d entretien et de
 Eviter de provoquer des étincelles avec les outils en travaillant sur dépannage, faire retirer les portes, panneaux, recouvrements ou
la batterie. dispositifs de protection uniquement par du personnel qualifié.
 Ne pas utiliser l’appareil de soudage pour charger des batteries ou  Pour empêcher tout démarrage accidentel pendant les travaux
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf d’entretien, débrancher le câble négatif (−) de batterie de la borne.
si l’appareil dispose d’une fonctionnalité de charge de batterie  Ne pas approcher les mains, cheveux, vêtements lâches et outils
destinée à cet usage. des organes mobiles.
 Observer la polarité correcte (+ et −) sur les batteries.  Remettre en place les portes, panneaux, recouvrements ou
 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dispositifs de protection à la fin des travaux d’entretien et avant de
dernier lieu. mettre le moteur en marche.
 Les sources d’étincelles, flammes nues, cigarettes et autres  Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
sources d’inflammation doivent être maintenues à l’écart des mise en route accidentelle du moteur.
batteries. Ces dernières produisent des gaz explosifs en  Bloquer le volant moteur pour éviter sa rotation lors d’une
fonctionnement normal et en cours de charge. intervention sur le générateur.
 Respecter les consignes du fabricant de la batterie pour LES ÉTINCELLES À L’ÉCHAPPEMENT
travailler sur une batterie ou à proximité. peuvent provoquer un incendie.
LE CARBURANT MOTEUR peut pro-  Empêcher les étincelles d’échappement du
voquer un incendie ou une explosion. moteur de provoquer un incendie.
 Utiliser uniquement un pare-étincelles
 Arrêter le moteur avant de vérifier le niveau de approuvé − voir codes en vigueur.
carburant ou de faire le plein.
 Ne pas faire le plein en fumant ou proche d’une source d’étincel- LES PIÈCES CHAUDES peuvent
les ou d’une flamme nue. provoquer des brûlures.
 Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.  Ne pas toucher des parties chaudes à mains
nues.
 Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.  Prévoir une période de refroidissement avant de
travailler à l’équipement.
 Jeter les chiffons dans un récipient ignifuge.
 Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
 Toujours garder le pistolet en contact avec le réservoir lors du dés et porter des gants de soudage et des vêtements épais pour
remplissage. éviter les brûlures.

OM-4435 Page 9
 LA VAPEUR ET LE LIQUIDE DE L’ACIDE DE LA BATTERIE peut pro-
REFROIDISSEMENT CHAUD peuvent voquer des brûlures dans les YEUX et
provoquer des brûlures. sur la PEAU.
 Il est préférable de vérifier le liquide de refroi-  Ne pas renverser la batterie.
dissement une fois le moteur refroidi pour éviter  Remplacer une batterie endommagée.
de se brûler.
 Rincer immédiatement les yeux et la peau à l’eau.
 Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si pré- LA CHALEUR DU MOTEUR peut pro-
cisé autrement dans la section maintenance du manuel du voquer un incendie.
moteur).
 Si le moteur est chaud et que le liquide doit être vérifié, opérer com-  Ne pas placer l’appareil sur, au-dessus ou à
me suivant. proximité de surfaces inflammables.
 Mettre des lunettes de sécurité et des gants, placer un torchon sur  Tenir à distance les produits inflammables de l’échappement.
le bouchon du radiateur.
 Dévisser le bouchon légèrement et laisser la vapeur s’échapper
avant d’enlever le bouchon.

L’utilisation d’un groupe autonome

à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
 Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisi-
ble et inodore.
 JAMAIS utiliser dans une maison ou garage,
même avec les portes et fenêtres ouvertes.
 Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.

2-4. Dangers liés à l’air comprimé

Un ÉQUIPEMENT PNEUMATIQUE risque MÉTAL CHAUD provenant du décou-
de provoquer des blessures ou même page ou du gougeage à l’arc risque de
la mort. provoquer un incendie ou une explo-
sion.
 Une installation ou une utilisation incorrecte de
cet appareil pourrait conduire à des dégâts
 Ne pas découper ou gouger à proximité de
matériels ou corporels. Seul un personnel
produits inflammables.
qualifié est autorisé à installer, utiliser et
entretenir cet appareil conformément à son  Attention aux risques d’incendie: tenir un extincteur à proximité.
manuel d’utilisation, aux normes industrielles et
aux codes nationaux, d’état ou locaux.
 Ne pas dépasser le débit nominal ou la capacité du compresseur L’AIR COMPRIMÉ risque de provoquer
ou de tout équipement du circuit d’air comprimé. Concevoir des blessures ou même la mort.
le circuit d’air comprimé de telle sorte que la défaillance
d’un composant ne risque pas de provoquer un accident  Avant d’intervenir sur le circuit d’air comprimé,
matériel ou corporel. couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
 Avant d’intervenir sur le circuit d’air comprimé, couper
et s’assurer que le circuit d’air ne peut être mis
l’alimentation électrique, verrouiller et étiqueter l’appareil,
sous pression par inadvertance.
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.  Détendre la pression avant de débrancher ou
de brancher des canalisations d’air.
 Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil
fonctionne. Seul un personnel qualifié est autorisé, et appliquant  Avant d’utiliser l’appareil, contrôler
les consignes du fabricant. les composants du circuit d’air comprimé,
les branchements et les flexibles en
 Ne pas modifier ou altérer le compresseur ou les équipements recherchant tout signe de détérioration, de fuite
fournis par le fabricant. Ne pas débrancher, désactiver ou et d’usure.
neutraliser les équipements de sécurité du circuit d’air
comprimé.  Ne pas diriger un jet d’air vers soi−même ou vers autrui.
 Utiliser uniquement des composants et accessoires  Pour intervenir sur un circuit d’air comprimé, porter un équipement
homologués par le fabricant. de protection tel que des lunettes de sécurité, des gants de cuir,
 Se tenir à l’écart de tout point présentant un danger de pincement une chemise et un pantalon en tissu résistant, des chaussures
ou d’écrasement créé par l’équipement raccordé au circuit d’air montantes et une coiffe.
comprimé.  Pour rechercher des fuites, utiliser de l’eau savonneuse ou
 Ne pas intervenir sous ou autour d’un équipement qui n’est un détecteur à ultrasons, jamais les mains nues. En cas
soutenu que par la pression pneumatique. Soutenir l’équipement de détection de fuite, ne pas utiliser l’équipement.
de façon appropriée par un moyen mécanique.
 Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
 En cas d’injection d’air dans la peau ou le corps, demander
immédiatement une assistance médicale.
OM-4435 Page 10
 détendre la pression et s’assurer que le circuit d’air ne peut être
L’INHALATION D’AIR COMPRIMÉ risque mis sous pression par inadvertance.
de provoquer des blessures ou même
 Demander seulement à un personnel qualifié d’enlever
la mort.
les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.
 Ne pas inhaler d’air comprimé.
 Utiliser l’air comprimé uniquement pour  Remettre en place les portes, panneaux, recouvrements ou
découper ou gouger ainsi que pour l’outillage dispositifs de protection à la fin des travaux d’entretien et avant
pneumatique. de mettre le moteur en marche.

Une PRESSION D’AIR RÉSIDUELLE DES PIÈCES CHAUDES peuvent

ET DES FLEXIBLES QUI FOUETTENT provoquer des brûlures graves.
risquent de provoquer des blessures.
 Ne pas toucher de pièces chaudes
 Détendre la pression pneumatique des outils et du compresseur ou du circuit d’air.
circuits avant d’entretenir, ajouter ou changer  Prévoir une période de refroidissement
des accessoires et avant d’ouvrir le bouchon avant d’intervenir sur l’équipement.
de vidange ou de remplissage d’huile
 Ne pas toucher aux pièces chaudes, utiliser les outils
du compresseur.
recommandés et porter des gants de soudage et
des vêtements épais pour éviter les brûlures.
Les PIÈCES MOBILES peuvent causer
des blessures. LIRE LES INSTRUCTIONS.
 S’abstenir de toucher des parties mobiles telles  Lire et appliquer les instructions sur les
que des ventilateurs, courroies et rotors. étiquettes et le Mode d’emploi avant
 Maintenir fermés et verrouillés les portes, l’installation, l’utilisation ou l’entretien de
panneaux, recouvrements et dispositifs l’appareil. Lire les informations de sécurité au
de protection. début du manuel et dans chaque section.
 Ne pas approcher les mains, cheveux, vêtements lâches et outils  N’utiliser que les pièces de rechange recommandées par le
des organes mobiles. constructeur.
 Avant d’intervenir sur le circuit d’air comprimé, couper  Effectuer l’entretien en respectant les manuels d’utilisation,
l’alimentation électrique, verrouiller et étiqueter l’appareil, les normes industrielles et les codes nationaux, d’état et locaux.

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

Risque D’INCENDIE OU LE SURCHAUFFEMENT peut
D’EXPLOSION. endommager le moteur électrique.
 Ne pas placer l’appareil sur, au-dessus ou  Arrêter ou déconnecter l’équipement avant de
à proximité de surfaces inflammables. démarrer ou d’arrêter le moteur.
 Ne pas installer l’appareil à proximité de pro-  Ne pas laisser tourner le moteur trop lentement sous risque d’en-
duits inflammables. dommager le moteur électrique à cause d’une tension et d’une fré-
 Ne pas surcharger l’installation électrique − s’assurer que l’ali- quence trop faibles.
mentation est correctement dimensionnée et protégée avant de  Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,
mettre l’appareil en service. s’il y a lieu.

LA CHUTE DE L’ÉQUIPEMENT LES ÉTINCELLES PROJETÉES

peut provoquer des blessures. peuvent provoquer des blessures.
 Utiliser l’anneau de levage pour lever l’appareil  Porter un écran facial pour protéger le visage et
et les accessoires correctement installées les yeux.
seuls, PAS les bouteilles de gaz. Ne pas dé-  Affûter l’électrode au tungstène uniquement à
passer le poids nominal maximal de l’œilleton la meuleuse dotée de protecteurs. Cette ma-
(voir les spécifications). nœuvre est à exécuter dans un endroit sûr lors-
 Utiliser un équipement de levage de capacité suffisante pour que l’on porte l’équipement homologué de pro-
lever l’appareil. tection du visage, des mains et du corps.
 En utilisant des fourches de levage pour déplacer l’unité, s’assu-  Les étincelles risquent de causer un incendie − éloigner toute
rer que les fourches sont suffisamment longues pour dépasser substance inflammable.
du côté opposé de l’appareil.
 Tenir l’équipement (câbles et cordons) à distance des véhicules Les PIÈCES MOBILES peuvent
mobiles lors de toute opération en hauteur. causer des blessures.
 Suivre les consignes du Manuel des applications pour l’équation  Ne pas s’approcher des organes mobiles.
de levage NIOSH révisée (Publication Nº94−110) lors du levage  Ne pas s’approcher des points de coincement
manuelle de pièces ou équipements lourds. tels que des rouleaux de commande.

OM-4435 Page 11
 LA SORTIE DE RECHARGE et L’EXPLO- LES CHARGES ÉLECTROSTATI-
SION DE LA BATTERIE peuvent QUES peuvent endommager les
provoquer des blessures. circuits imprimés.
La recharge de batterie n’existe pas sur tous les  Établir la connexion avec la barrette de terre
modèles. avant de manipuler des cartes ou des pièces.
 Utiliser des pochettes et des boîtes antistatiques pour stocker,
 Toujours porter une protection faciale, des gants en caoutchouc déplacer ou expédier des cartes de circuits imprimes.
et vêtements de protection lors d’une intervention sur la batterie.
 Arrêter le moteur avant de débrancher ou de brancher des UNE REMORQUE QUI BASCULE peut
câbles de batterie, des câbles de chargeur de batterie (le cas provoquer des blessures.
échéant) ou de batterie d’entretien.  Utiliser les supports de la remorque ou des
 Eviter de provoquer des étincelles avec les outils en travaillant blocs pour soutenir le poids.
sur la batterie.  Installer convenablement le poste sur la remor-
 Ne pas utiliser l’appareil de soudage pour charger des batteries que comme indiqué dans le manuel s’y rappor-
ou faire démarrer des véhicules à l’aide de câbles de démarrage, tant.
sauf si l’appareil dispose d’une fonctionnalité de charge de
batterie destinée à cet usage. LIRE LES INSTRUCTIONS.
 Observer la polarité correcte (+ et −) sur les batteries.
 Lire et appliquer les instructions sur les
 Débrancher le câble négatif (−) en premier lieu. Le rebrancher en
étiquettes et le Mode d’emploi avant
dernier lieu.
l’installation, l’utilisation ou l’entretien de
 Les sources d’étincelles, flammes nues, cigarettes et autres l’appareil. Lire les informations de sécurité au
sources d’inflammation doivent être maintenues à l’écart des début du manuel et dans chaque section.
batteries. Ces dernières produisent des gaz explosifs en
 N’utiliser que les pièces de rechange recommandées par le
fonctionnement normal et en cours de charge.
constructeur.
 Respecter les consignes du fabricant de la batterie pour
 Effectuer l’entretien en respectant les manuels d’utilisation,
travailler sur une batterie ou à proximité.
les normes industrielles et les codes nationaux, d’état et locaux.
 Les opérations de charge de batterie ne doivent être effectuées
que par des personnes qualifiées.
LE RAYONNEMENT HAUTE FRÉ-
 Pour enlever la batterie d’un véhicule pour la recharge, QUENCE (H.F.) risque de provoquer
débrancher tout d’abord le câble négatif (−) et le rebrancher en
dernier lieu. Pour éviter un arc, s’assurer que tous les
des interférences.
accessoires sont débranchés.  Le rayonnement haute fréquence (H.F.) peut
 Ne charger que des batteries plomb−acide. Ne pas utiliser le provoquer des interférences avec les équipe-
chargeur de batterie pour alimenter un autre circuit électrique ments de radio−navigation et de communica-
basse tension ou pour charger des batteries sèches. tion, les services de sécurité et les ordinateurs.
 Ne pas charger une batterie gelée.  Demander seulement à des personnes qualifiées familiarisées
 Ne pas utiliser de câbles de charge endommagés. avec des équipements électroniques de faire fonctionner l’installa-
 Ne pas charger des batteries dans un espace fermé ou en tion.
l’absence d’une ventilation.  L’utilisateur est tenu de faire corriger rapidement par un électricien
 Ne pas charger une batterie dont les bornes sont desserrées ou qualifié les interférences résultant de l’installation.
présentant une détérioration comme par exemple un boîtier ou  Si le FCC signale des interférences, arrêter immédiatement l’ap-
un couvercle fissuré. pareil.
 Avant de charger une batterie, sélectionner la tension de charge  Effectuer régulièrement le contrôle et l’entretien de l’installation.
correspondant à la tension de la batterie.  Maintenir soigneusement fermés les portes et les panneaux des
 Régler les commandes de charge de batterie sur la position sources de haute fréquence, maintenir les éclateurs à une distan-
d’arrêt avant de brancher la batterie. Veiller à ce que les pinces ce correcte et utiliser une terre et un blindage pour réduire les
de charge ne se touchent pas. interférences éventuelles.
 Ranger les câbles de charge à distance du capot, des portes et
des pièces mobiles du véhicule. LE SOUDAGE À L’ARC risque de
provoquer des interférences.
 L’énergie électromagnétique risque de provo-
quer des interférences pour l’équipement élec-
tronique sensible tel que les ordinateurs et
LES FILS DE SOUDAGE peuvent l’équipement commandé par ordinateur tel que
provoquer des blessures. les robots.
 Ne pas appuyer sur la gâchette avant d’en  Veiller à ce que tout l’équipement de la zone de soudage soit
avoir reçu l’instruction. compatible électromagnétiquement.
 Ne pas diriger le pistolet vers soi, d’autres per-  Pour réduire la possibilité d’interférence, maintenir les câbles de
sonnes ou toute pièce mécanique en enga- soudage aussi courts que possible, les grouper, et les poser
geant le fil de soudage. aussi bas que possible (ex. par terre).
 Veiller à souder à une distance de 100 mètres de tout équipe-
L’EMPLOI EXCESSIF peut ment électronique sensible.
SURCHAUFFER L’ÉQUIPEMENT.  Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
 Laisser l’équipement refroidir ; respecter le fac-
 En cas d’interférences après avoir pris les mesures précéden-
teur de marche nominal.
tes, il incombe à l’utilisateur de prendre des mesures supplé-
 Réduire le courant ou le facteur de marche mentaires telles que le déplacement du poste, l’utilisation de câ-
avant de poursuivre le soudage. bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
 Ne pas obstruer les passages d’air du poste. teurs dans la zone de travail.

OM-4435 Page 12
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
Les gaz d’échappement des moteurs contiennent des pro-
dont l’État de Californie reconnaît qu’ils provoquent des mal-
duits chimiques dont l’État de Californie reconnaît qu’ils
formations congénitales et, dans certains cas, des cancers.
provoquent des cancers et des malformations congénitales
(Code de santé et de sécurité de Californie, chapitre 25249.5
ou autres problèmes de procréation.
et suivants)
Pour les moteurs diesel :
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi- Les gaz d’échappement des moteurs diesel et certains de
ques dont l’État de Californie reconnaît qu’ils provoquent des leurs composants sont reconnus par l’État de Californie com-
cancers et des malformations congénitales ou autres me provoquant des cancers et des malformations
problèmes de procréation. Se laver les mains après manipu- congénitales ou autres problèmes de procréation.
lation.

Ce produit contient des produits chimiques, notamment du

plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.

2-7. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
is available as a free download from the American Welding Society at www.csa-international.org).
http://www.aws.org or purchased from Global Engineering Documents
Safe Practice For Occupational And Educational Eye And Face Protec-
(phone: 1-877-413-5184, website: www.global.ihs.com).
tion, ANSI Standard Z87.1, from American National Standards Institute,
Safe Practices for the Preparation of Containers and Piping for Welding 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
and Cutting, American Welding Society Standard AWS F4.1, from Glob- site: www.ansi.org).
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Safe Practices for Welding and Cutting Containers that have Held Com-
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.)
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
www.nfpa.org and www. sparky.org). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
www.osha.gov).
from Compressed Gas Association, 14501 George Carter Way,
Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, Portable Generators Safety Alert, U.S. Consumer Product Safety Com-
website:www.cganet.com). mission (CPSC), 4330 East West Highway, Bethesda, MD 20814
Safety in Welding, Cutting, and Allied Processes, CSA Standard (phone: 301-504-7923, website: www.cpsc.gov/cpscpub/pubs/port-
W117.2, from Canadian Standards Association, Standards Sales, 5060 gen.pdf).
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: Applications Manual for the Revised NIOSH Lifting Equation, The Na-
800-463-6727, website: www.csa-international.org). tional Institute for Occupational Safety and Health (NIOSH), 1600
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
Standards Association, Standards Sales, 5060 Spectrum Way, Suite www.cdc.gov/NIOSH).

2-8. Informations relatives aux CEM

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

OM-4435 Page 13
 SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

 Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

Safe1 2012−05

Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

Safe2 2012−05

Protect yourself from electric shock by insulating yourself from work and ground.

Safe3 2012−05

Keep your head out of the fumes.

Safe6 2012−05

Use forced ventilation or local exhaust to remove the fumes.

Safe8 2012−05

Use ventilating fan to remove fumes.

Safe10 2012−05

Keep flammables away from welding. Do not weld near flammables.

Safe12 2012−05

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe14 2012−05

Do not weld on drums or any closed containers.

Safe16 2012−05

Do not remove or paint over (cover) the label.

Safe20 2012−05

OM-4435 Page 14
 Do not work on unit if engine is running. Stop engine first.

Safe21 2012−05

Do not smoke while fueling or if near fuel.

Safe22 2012−05

Stop engine before fueling.

Safe23 2012−05

Do not fuel a hot engine.

Safe24 2012−05

Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye
rating (see Specifications).

Safe25 2012−05

Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.

Safe38 2012−05

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

Become trained and read the instructions before working on the

machine or welding.

Safe40 2012−05

Engine fuel plus flames or sparks can cause fire.

=
Safe45 2012−05

Remove unit from shipping crate. Remove Owner’s Manual from unit.
Follow instructions to install muffler.

Safe46 2012−05

Read Owner’s Manual. Read labels on unit.

Safe47 2012−05

Read Owner’s Manual. Follow instructions to activate battery.

Safe48 2012−05

OM-4435 Page 15
 0 - 50 h std
During the first 50 hours of operation keep welding load above 200
amperes. Do not weld below 200 amperes of output.

Safe54 2012−05

50 h std
After the first 50 hours of operation, change the engine oil and filter.

Safe55 2012−05

Hazardous voltage remains on input capacitors after power is turned

V off. Do not touch fully charged capacitors. Always wait 60 seconds
V after power is turned off before working on unit, OR check input ca-
pacitor voltage, and be sure it is near 0 before touching any parts.

>60s V Safe42 2012−05

Never use generator inside a home or garage, even if doors and win-
dows are open.

Safe87 2012−07

Only use generator outside and far away from windows, doors, and
vents.

Safe88 2012−07

Do not use ether. Using ether voids warranty. See engine Owner’s Manual.

Safe89 2012−07

Hot muffler and exhaust pipe can cause severe burns.

Safe90 2012−07

Welding, cutting, drilling, or grinding on base can cause fire or explosion.

Safe91 2012−07

OM-4435 Page 16
3-2. Miscellaneous Symbols And Definitions
 Some symbols are found only on CE products.

Fast (Run, Weld/

Stop Engine Slow (Idle) Start Engine
Power)

Starting Aid
Battery (Engine) Engine Coolant Engine Oil
(Preheat)

Check Injectors/ Check Valve Protective Earth

Fuel
Pump Clearance (Ground)

Certified/Trained
Positive Negative Welding Arc
Mechanic

A Amperes
V Volts Arc Force (Dig) Remote

Air Temperature Or
Alternating
Engine Engine Output
Current
Temperature

Stick (SMAW) MIG (GMAW) TIG (GTAW)

Lift-Arc TIG
Welding Welding Welding

h s 1
Time Hours Seconds Single Phase

3
Read Operator’s Direct Current
Three Phase Circuit Protection
Manual (DC)

Engine-Driven,

P1max Maximum Power

Consumption
Work Connection G
3
Three-Phase
Alternator With
Rectifier
Hz Hertz

X Duty Cycle
U0 Rated No Load
Voltage (Average) U2 Conventional
Load Voltage
n
Rated Load
Speed

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

Suitable For Weld-

S
ing In An Environ- Remote Foot
Contactor On ment With In- Hour Meter Control TIG
creased Risk Of (GTAW)
Electric Shock

Call For Mainten- Voltage Sensing

Check Air Cleaner Air Filter
ance Feeder

Sound Level

OM-4435 Page 17
 SECTION 4 − SPECIFICATIONS
4-1. Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)

! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.

 The EMF assessment on this equipment was conducted at 0.5 meter.

 At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values. ce-emc 1 2010−10

B. Information On Electromagnetic Compatibility (EMC)

! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con-
ducted as well as radiated disturbances.
ce-emc 3 2011-09

4-2. Weld, Power, And Engine Specifications

Maximum
Welding Weld Output Rated Welding Open- Fuel
Auxiliary Power Rating Engine
Mode Range Output Circuit Capacity
Voltage

300 A, 32 Volts DC Generator

60% Duty Cycle Single-Phase,
20 − 410 A
CC/DC 10 kVA/kW, 91/46 A,
250 A, 30 Volts DC 110/220 V AC,
100% Duty cycle 60 Hz Caterpillar C1.5
Water−Cooled 11.5 gal
73
Receptacles Three−Cylinder (43.5 L)
300 A, 29 Volts DC
110/55 V AC Receptacles 21.7 HP Diesel Engine
CV/DC 60% Duty Cycle
14 − 40 V 5.5 kVA/kW, 50/100 A
Flux Core 250 A, 26.5 Volts DC
220/110 V AC Receptacles
100% Duty cycle
11 kVA/kW, 50/20 A

4-3. Environmental Specifications

IP Rating Operating Temperature Range
IP23S
This equipment is designed for outdoor use. It may be stored, but is −40 to 104 °F (−40 to +40°C)
not intended to be used outside during precipitation unless sheltered.

OM-4435 Page 18
4-4. Dimensions, Weights, And Operating Angles
Dimensions
32 in. (813 mm) G
Height 35-3/4 in. (908 mm)
(to top of lift eye)
26-1/4 in. (667 mm)
(mtg. brackets turned in)
Width ! Do not exceed tilt angles or engine could
28-3/4 in. (730 mm)
(mtg. brackets turned out) be damaged or unit could tip.

Depth 56 in. (1422 mm) ! Do not move or operate unit where it could
tip.
A 56 in. (1422 mm)
B 54 in. (1372 mm) A
B C
C 52 in in. (1321 mm)
D 2 in. (51 mm)
E 26 in. (660 mm)
F 7/8 in. (22 mm)
30°
G 27-3/4 in. (705 mm)
H 30°
H 9/16 in. (14 mm) Dia. 4 Holes
Front Panel End 20°
Weight 20°
No fuel: 1128 lb (512 kg) D F
w/ fuel: 1210 lb (549 kg) E
Lifting Eye Weight Rating:
2000 lb (907 kg) Maximum

4-5. Duty Cycle And Overheating

1 100% Duty Cycle
1 Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.

 This unit is rated for welding at

250 amperes continuously.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.

1000
800
600
WELD AMPERES

500
400
CC
300 CV
250
200

150

100
10 15 20 25 30 40 50 60 80 100
% DUTY CYCLE

217 515

OM-4435 Page 19
4-6. Volt-Ampere Curves
C. Stick Mode The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
100 other settings fall between the
90 curves shown.
80
70
60
DC Volts

50
Max
40
Min
30
20
10
0
0 100 200 300 400 500 600
DC Amperes

D. MIG Mode

100
90
80
70
60
DC Volts

50
Max
40
30
20 Min
10
0
0 100 200 300 400 500 600
DC Amperes

E. TIG Mode

100
90
80
70
60
DC Volts

50
40
30
20
10
0
0 100 200 300 400 500
DC Amperes

237 466 / 237 468 / 237 470

OM-4435 Page 20
4-7. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.

2.00
1.75
1.50
U.S. GAL/HR.

1.25
1.00
0.75
0.50
0.25 IDLE
0.00
0 50 100 150 200 250 300 350 400
DC WELD AMPERES AT 100% DUTY CYCLE

237 471

4-8. AC Generator Power Curve

The AC power curve shows the
generator power in amperes.

240 120

200 100

160 80
AC VOLTS

120 60

80 40

40 20

0 0
0 20 40 60 80 100 120 140
AC AMPERES IN 110V MODE
0 10 20 30 40 50 60 70
AC AMPERES IN 220V MODE

220 346−B

OM-4435 Page 21
 SECTION 5 − INSTALLATION
5-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

5-2. Installing Welding Generator

! Do not move or operate unit
where it could tip.
! Always securely fasten weld-
ing generator onto transport
Movement vehicle or trailer and comply
with all DOT and other applica-
ble codes.
NOTICE − Do not install unit where
air flow is restricted or engine may
overheat.

 See Section 4-4 for lifting eye rat-

ing.

 See Section 5-3 for mounting

information.

OR OR

Location/Airflow Clearance

OR OR

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

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

install3 2008-01 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

OM-4435 Page 22
5-3. Mounting Welding Generator
! Do not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
Supporting The Unit
NOTICE − Do not mount unit by
supporting the base only at the four
mounting brackets. Use cross-
supports to adequately support unit
and prevent damage to base.
Mounting Surface:
2 1 Cross-Supports
2 Mounting Brackets (Supplied)
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brack-
OR
ets.
3 1/2 in. Bolt And Washer
(Minimum − Not Supplied)
4 3/8-16 x 1 in. Screws
1 (Supplied)
To Bolt Unit In Place:
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
1 Mount unit to truck or trailer with 1/2
in. (12 mm) or larger hardware (not
supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
Using Mounting Brackets

Welding Unit In Place

Bolting Unit In Place

2 3

Tools Needed:
9/16 in. install3 2008--01 803 274 / 200 864-A / 803 231

OM-4435 Page 23
5-4. Grounding Generator To Truck Or Trailer Frame

1 2

GND/PE

rot_grnd1 2012−03 − 800 652-D

! Always ground generator frame to frame. Always connect a ground 1 Equipment Grounding Terminal (On
vehicle frame to prevent electric wire from the generator equipment Front Panel)
shock and static electricity hazards. grounding terminal to bare metal on 2 Grounding Cable (Not Supplied)
the vehicle frame as shown.
! Also see AWS Safety & Health Fact 3 Metal Vehicle Frame
Sheet No. 29, Grounding of Portable Connect cable from equipment ground
And Vehicle Mounted Welding Gen- ! Use GFCI protection when operat- terminal to metal vehicle frame. Use #8
erators. ing auxiliary equipment. If unit does AWG or larger insulated copper wire.
not have GFCI receptacles, use
! Bed liners, shipping skids, and GFCI-protected extension cord. Do  Electrically bond generator frame to
some running gear insulate the not use GFCI receptacles to power vehicle frame by metal-to-metal con-
welding generator from the vehicle life support equipment. tact.

Notes

OM-4435 Page 24
5-5. Installing Exhaust Pipe
! Stop engine and let cool.
 Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.

Tools Needed:
1/2 in. 803 582 / Ref. 287 125-A

5-6. Connecting The Battery

! Connect negative (−) battery
cable last.

 Close door after connecting

battery.

Tools Needed:
1/2 in. 803 563 / Ref. 287 125-A / S-0756-C

OM-4435 Page 25
5-7. Engine Prestart Checks
 Follow run-in procedure in engine manual. If unburned
fuel and oil collect in exhaust pipe during run-in, see
Section 10.
Check radiator coolant
level when fluid is low in
recovery tank.

Full
Full

Diesel

Capacity:
6 qt (5.7 L)
 Engine stops if fuel level is low.

Coolant Recovery Tank

Hot Full

Cold Full

Full

Ref. 804 009−C

 Check all engine fluids daily.  Engine stops if fuel level is low. freeze to mixture if using the unit in tempera-
tures below −34° F (−37° C).
Engine must be cold and on a level surface.
Oil
Automatic shutdown system stops engine if Keep radiator and air intake clean and free
oil pressure is too low or coolant tempera- After fueling, check oil with unit on level sur- of dirt.
ture is too high. face. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
 This unit has a low oil pressure shut- NOTICE − Incorrect engine temperature
down switch. However, some condi- can damage engine. Do not run engine with-
Coolant out a properly working thermostat and ra-
tions may cause engine damage before
the engine shuts down. Check oil level diator cap.
Check coolant level in radiator before start-
often and do not use the oil pressure ing unit the first time. If necessary, add cool-
shutdown system to monitor oil level. ant to radiator until coolant level is at bottom  To improve cold weather starting:
Follow run-in procedure in engine manual. of filler neck.
If unburned fuel and oil collect in exhaust Use Preheat switch (see Section 6-1).
pipe during run-in, see Section 10. Check coolant level in recovery tank daily.
Fuel If necessary, add coolant to recovery tank Keep battery in good condition. Store
until coolant level is between Cold Full and battery in warm area.
NOTICE − Do not use gasoline. Gasoline Hot Full levels. If recovery tank coolant level
will damage engine. was low, also check coolant level in radiator. Use fuel formulated for cold weather
The unit is shipped with enough fuel to pre- Add coolant if level is below bottom of radia- (diesel fuel can gel in cold weather).
vent air from entering fuel system. Add fresh tor filler neck. Contact local fuel supplier for fuel in-
diesel fuel before starting (see engine main- formation.
tenance label for fuel specifications). Leave Unit is shipped with an engine coolant mix-
filler neck empty to allow room for ture of water and ethylene glycol base anti- Use correct grade oil for cold weather
expansion. freeze rated to −34° F (−37° C). Add anti- (see Section 8-1).

OM-4435 Page 26
5-8. Connecting To Weld Output Terminals
Stick and TIG Welding MIG and FCAW Welding
For Stick and TIG welding Direct Current Elec- For MIG and FCAW welding Direct Current
trode Positive (DCEP), connect electrode Electrode Positive (DCEP), connect wire
holder cable to Positive (+) terminal and work feeder cable to Positive (+) terminal and work
cable to Negative (−) terminal on left. cable to Negative (−) terminal on left. Use Pro-
cess switch to select type of weld output (see
For Direct Current Electrode Negative
Section 6-3).
(DCEN), reverse cable connections.
For Direct Current Electrode Negative
Use Process switch to select type of weld out-
(DCEN), reverse cable connections.
put (see Section 6-3).

! Stop engine.
! Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.

 Do not place anything between weld cable

terminal and copper bar. Make sure that
the surfaces of the weld cable terminal
and copper bar are clean.
1 Correct Weld Cable Connection
2 Incorrect Weld Cable Connection
3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output termi-
nal. Slide weld cable terminal onto weld output
terminal and secure with nut so that weld cable
terminal is tight against copper bar.
7 Work (−) Weld Output Terminal
8 Positive (+) Weld Output Terminal(s)

7 8
1

6
3

Tools Needed:
3/4 in. Ref.804 009-F / Ref. 287 125-A / 803 778-B

OM-4435 Page 27
5-9. Selecting Weld Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
! Stop engine before
connecting to weld
output terminals.
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
! Do not use worn, 100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
damaged, under-
sized, or poorly
spliced cables.
10 − 60% 60 − 100%
Welding
Duty Duty 10 − 100% Duty Cycle
Amperes
Cycle Cycle
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

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

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

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

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

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

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

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

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-J 2011−07

Notes

OM-4435 Page 28
5-10. Connecting To Remote 14 Receptacle RC14

Socket* Socket Information

A 24 volts AC. Protected by sup-

plementary protector CB8.
24 VOLTS AC
B Contact closure to A completes
24 volt AC contactor control
circuit.

C Output to remote control:+10

volts DC in MIG mode; 0 to +10
volts DC in Stick or TIG mode.

REMOTE D Remote control circuit common.

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

Current feedback: 1 volt per

F 100 amperes.

H Voltage feedback: 1 volt per 10

OR arc volts.

GND K Chassis common.

NEUTRAL G Circuit common for 24 volt AC

Ref 804 009-F
circuit.

*The remaining sockets are not used.

Notes

OM-4435 Page 29
 SECTION 6 − OPERATING WELDING GENERATOR

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

6 7 8 9 1 2 3 4

287 125−B / 804 009−F

OM-4435 Page 30
6-2. Description Of Front Panel Controls (See Section 6-1)

Engine Starting Controls 4 Engine Indicator Light 7 Voltage/Amperage Control

1 Preheat Switch Light goes on and engine stops if engine tem- With Process/Contactor switch in any Stick or
Use switch to energize starting aid for cold perature exceeds 230° F (110° C) or engine TIG setting, use control to adjust amperage.
weather starting (see starting instructions fol- oil pressure is below 10 psi (69 kPa). With Process/Contactor switch in any Wire
lowing). (MIG) position, use control to adjust voltage.
 Normal engine temperature is 180 - 203 With Voltage/Amperage Adjust Switch in Re-
2 Engine Control Switch F (82 - 95 C). Normal oil pressure is 30 mote position, control limits the remote am-
Use switch to start engine, select engine run, - 60 psi (207 - 414 kPa). perage in Stick or TIG mode, but has no effect
and stop engine. NOTICE − Do not run engine until trouble is in Wire (MIG) modes.
In Run position, engine runs at weld/power fixed.
Weld Meters (Optional)
speed. Weld Controls
To Start: 5 Remote Control Receptacle  Weld meters also work in combination to
display troubleshooting help codes (see
NOTICE − Do not use ether. Use receptacle to connect remote controls, Section 8-10).
wire feeders, and tools.
 If engine does not start, let engine come 8 DC Voltmeter
to a complete stop before attempting re- When a remote control is connected to the
start. Remote receptacle, the Auto Sense Remote Voltmeter displays preset voltage (MIG weld-
feature automatically switches voltage/am- ing) with contactor off, and actual output volt-
Above 325 F (05 C): turn Engine Control perage control to the remote control (see Sec- age with the contactor on. Voltmeter displays
switch to Start. Release Engine Control tion 5-10). voltage at the weld output terminals, but not
switch when engine starts. necessarily the welding arc due to resistance
With remote control connected, weld output is
Below 325 F (05 C): turn engine control switch of cable and connections.
determined by a combination of front panel
to Run position. Push Preheat switch up for and remote control voltage/amperage set- To set voltage, turn contactor off and turn Pro-
60 seconds. Turn Engine Control switch to tings. cess/Contactor switch to Wire position. Turn
Start. Release Engine Control switch and V/A control until desired voltage is displayed
Preheat switch when engine starts. If no remote control is connected to the Re-
mote receptacle, the front panel Voltage/Am- on Voltmeter. When welding is finished, volt-
To Stop: turn Engine Control switch to Off perage control adjusts voltage and amper- meter displays weld voltage and then defaults
position. age. to preset voltage.
Engine Gauges, Meters, And Lights 9 DC Ammeter
 If a remote device connected to Remote
 See Section 6-6 for complete fuel/hour Receptacle RC14 is faulty or is discon- Ammeter displays preset amperage (Stick
gauge information. nected during operation, the meters dis- and TIG only) when not welding, and actual
play Help 25 (see Section 8-10). Clear output amperage when welding.
3 Fuel Gauge/Hourmeter fault by stopping and restarting the unit or
by turning Process/Contactor switch to To set amperage, turn Process/Contactor
Use gauge to check fuel level or total engine
another position. switch to Stick or TIG position. Turn V/A con-
operating hours, or hours to oil change..
trol until desired amperage is displayed on
To check fuel level or engine hours when en- 6 Process/Contactor Switch Ammeter. When welding is finished, ammeter
gine is not running, turn Engine Control switch See Section 6-3 for Process/Contactor displays weld amperage and then defaults to
to Run position. switch information. preset amperage.

OM-4435 Page 31
6-3. Process/Contactor Switch
! Weld output terminals are en-
ergized when Process/Con-
tactor switch is in a Weld Ter-
minals Always On position
and the engine is running.
1 Process/Contactor Switch
2 Weld Terminals Always On −
TIG Lift Arc Position
1
3 Remote On/Off Switch
Required − TIG HF Required
Or Scratch Start Position
4 Remote On/Off Switch
Required − Wire (Flux Core)
Position
5 Weld Terminals Always On −
6 Wire (Flux Core) Position
6 Weld Terminals Always On −
Stick − Position
5 Use switch to select weld process
2 and weld output on/off control (see
table below).
3 Place switch in Remote On/Off
4
Switch Required positions to turn
weld output on and off with a device
connected to the Remote 14 recep-
tacle.
Place switch in Weld Terminals Al-
ways On positions for weld output to
be on whenever the engine is run-
ning.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc
TIG starting procedure (see Section
6-4).

Ref 804 444−C / Ref 287 125−A

Process/Contactor Switch Settings

Switch Setting Process Output On/Off Control

Weld Terminals
TIG Lift-Arc (GTAW) Electrode Hot
Always On − TIG Lift Arc −

Remote On/Off Switch Required − TIG HF GTAW With HF Unit, Pulsing Device, Or Remote
At Remote 14 Receptacle
Required Or Scratch Start Control

Remote On/Off Switch Required − Wire (Flux Flux Core

At Remote 14 Receptacle
Core) w/Constant Speed Feeder

Flux Core
Weld Terminals Always On − Wire (Flux Core) Electrode Hot
w/Voltage Sensing Feeder

Stick (SMAW),
Weld Terminals Always On − Stick Electrode Hot
Air Carbon Arc (CAC-A) Cutting And Gouging

OM-4435 Page 32
6-4. Lift-Arct TIG With Crater-Out And Auto-Stopt
Arc Start With Lift-Arc TIG
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted.
Select Lift-Arc at Process/Contac-
tor switch.
Arc Start With Lift-Arc
Turn gas on.
1 2 1 Touch or scratch.
2 Lift at any angle.
Touch tungsten electrode to
workpiece at weld start point.
Slowly lift electrode. Arc is started
when electrode is lifted.
Maintain shielding gas coverage
and eliminate tungsten and work-
piece contamination by using
Auto-Crater or Auto-Stop to end
the arc.
Arc End With Crater-Out:

 Momentary contact switch re-

quired to start crater-out.
1 While welding.
Arc End With Crater-Out 2 Close momentary contact
switch to start Crater-out end
1 2 3 (current is reduced).
3 Shielding gas continues until
shut off.
Arc End With Auto-Stop:
1 While welding.
2 Lift torch to start Auto-Stop.
Arc stops.
3 Move torch back down to
maintain gas coverage and
prevent contamination.

OR

Arc End With Auto-Stop

1 2 3

WM Marketing

OM-4435 Page 33
6-5. Remote Voltage/Amperage Control

1 Remote 14 Receptacle RC14

Connect optional remote control to
RC14 (see Section 5-10).

 When a remote control is con-

nected to the Remote receptacle,
the Auto Sense Remote feature
automatically switches voltage/
amperage control to the remote
1
control. When a device is con-
nected to the Remote receptacle,
remote voltage/amperage con-
2 3 trol is always available regard-
less of the position of the Pro-
cess/Contactor switch.
2 Voltmeter
3 Ammeter

Example: Remote Voltage Control (FCAW)

Voltmeter Toggles Between

28
Ammeter Shows Zero
Preset And Actual Output
When Not Welding, Actual
Voltage While Welding
0

Connect Remote Set Remote Process Adjust Optional Remote Control

Control To Remote (Only If Remote On/Off
Receptacle RC14 Control Is Desired)

Example: Combination Remote Amperage Control (TIG)

Voltmeter Shows Open-Circuit Ammeter Shows Preset

Voltage When Not Welding, Arc
Voltage While Welding 56 205 Output When Not Welding,
Actual Amperage While
Welding In Example:
Process =Remote TIG
Min = 20 A DC
Max = About 205 A DC

Max (205 A DC)

Min (20 A DC)

Connect Remote Set Remote Process Set V/A Control
Adjust Optional Remote Control
Control To Remote (Only If Remote On/Off Mid-Range: About 205 A
Receptacle RC14 Control Is Desired)

0774 / Ref.287 125−A / Ref 804 444−A

OM-4435 Page 34
6-6. Fuel/Hour Gauge Descriptions

OM-4435 Page 35
6-7. Optional Engine Block Heater Operation

1 Engine Block Heater Plug

Use heater to maintain a constant
engine coolant temperature.
To turn on heater, connect heater
Coolant Heater plug to 120 volts AC receptacle.
Specifications
! Do not run engine while en-
Watts Volts ±10% gine block heater is on.
NOTICE −In extremely cold weath-
1000 120 er, heater should be connected to
power source when engine is
warm.
! The area near the engine
block heater gets hot.
Disconnect plug to turn off heater.

Coolant heater1 2012−05 803 562 / Ref. 803 145

Notes

OM-4435 Page 36
 SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Auxiliary Power Receptacles

1 2 3 4 5 6

Ref. 287 125-A

! Use GFCI protection when operating ! Test GFCI monthly. See Section 7-2 Receptacles GFCI1, RC11, and RC12
auxiliary equipment. If unit does not for GFCI information and for reset- supply 60 Hz single-phase power at weld/
have GFCI receptacles, use GFCI- ting and testing procedures. power speed.
protected extension cord. Do not
3 Supplementary Protector CB5 Maximum combined output of all recep-
use GFCI receptacle to power life
support equipment. CB5 protects GFCI1 from overload. If a tacles is 10 kVa/kW.
supplementary protector opens, the recep-
! Unplug power cord before attempt- tacle does not work. Press button to reset.  At least once a month, run engine at
ing to service accessories or tools. weld/power speed and press test but-
4 Earth Leakage Circuit Breaker ELCB1 ton to verify ELCBs are working prop-
1 220V 16 A AC Receptacle RC12 5 Earth Leakage Circuit Breaker ELCB2 erly.
2 110V 20 A AC Receptacle GFCI1 ELCB1 protects RC12 and ELCB2 protects  If a supplementary protector or circuit
RC11 from overload and earth leakage breaker continues to open, contact
GFCI1 supplies 60 Hz single-phase power fault. If a circuit breaker opens, the recep-
at weld/power speed. Factory Authorized Service Agent.
tacle does not work. Place switch in On
Maximum output from GFCI1 is 2.4
position to reset circuit breaker.  Generator power decreases as weld
kVA/kW. 6 220V 32A AC Receptacle RC11 output increases.

OM-4435 Page 37
7-2. GFCI Receptacle Information, Resetting And Testing

2
3
4
! Test and reset GFCI
only at Run speed.

RotGFCI1 2012−05

! Use GFCI protection when operat- If a ground fault is detected, the GFCI Reset Check for damaged or wet tools, cords,
ing auxiliary equipment. If unit does button pops out, and the circuit opens to plugs, etc. connected to the receptacle.
not have GFCI receptacles, use disconnect power to the faulty equipment. Start engine and operate at Run (weld/
GFCI-protected extension cord. Do A GFCI receptacle does not protect against power) speed. Press GFCI Reset button.
not use GFCI receptacle to power circuit overloads, short circuits, or shocks Reconnect equipment to GFCI receptacle.
life support equipment. not related to ground faults. Reset and test If GFCI Reset button pops out again, check
GFCI receptacle according to the following the equipment and repair or replace if faulty.
! Unplug power cord before attempt- procedures.
ing to service accessories or tools. Testing GFCI Receptacles
Resetting/Testing GFCI Receptacle
1 120 V 20 A AC GFCI Receptacle
! Test GFCI monthly. See Testing
 GFCI testing must be done with engine
2 GFCI Receptacle Test Button GFCI Receptacle. running at Run (weld/power) speed.

! Do not test or reset GFCI recept- Start engine and operate at Run (weld/
3 GFCI Receptacle Reset Button
acles at idle speed/low voltage or power) speed.
4 GFCI Indicator Light (LED) the GFCI will be damaged and not Press the GFCI Test button. The GFCI Re-
provide protection from electric set button should pop out.
GFCI Receptacles shock caused by a ground fault.
Press the GFCI Reset button.
GFCI receptacles protect the user from ! If LED blinks, stop using GFCI re-
electric shock if a ground fault occurs in ceptacle and have it replaced by a Have GFCI replaced by a Factory Au-
equipment connected to the receptacle. A Factory Authorized Service Agent. thorized Service Agent if any of the fol-
ground fault occurs when electrical current lowing occur:
Resetting GFCI Receptacles
takes the shortest path to ground (which GFCI does not trip when tested
could be through a person) rather than fol- If a GFCI fault occurs, stop engine and dis- LED blinks
low its intended safe path. connect equipment from GFCI receptacle. GFCI does not reset.

OM-4435 Page 38
 SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Maintenance Label

Caterpillar Corporate Headquarters

100 North East Adams Street
Peoria, Illinois USA 61629
(309) 675−1000
http://www.cat.com/engines
Cat Dealer Locator:
Use website to find local engine service facility.

Service 2 If your problem cannot be resolved at Please follow the above steps in sequence
the dealer level without additional if a problem arises.
When a problem arises concerning the op-
assistance, call a Field Service
eration or service of the engine, the prob- Website Address
Coordinator at 1-800-447-4986.
lem will normally be managed by the dealer
in your area. 3 If your needs still have not been met, www.caterpillar.com
submit the matter in writing to:
Your satisfaction is a primary concern to
Caterpillar and to Caterpillar dealers. If you Altitude
Caterpillar Inc.
have a problem that has not been handled Manager, Customer Service, Contact the Caterpillar applications depart-
to your complete satisfaction, follow these Engine Division ment for information on the effect of ambient
steps: Mossville Bldg A conditions on Caterpillar engines.
1 Discuss your problem with a manager P.O. Box 600
from the dealership. Peoria, IL 61552-0600

OM-4435 Page 39
8-2. Routine Maintenance
! Stop engine before maintaining.
 See Engine Manual and Maintenance Label
Recycle engine for important start-up, service, and storage
fluids. information. Service engine more often if
used in severe conditions.

 = Check  = Change  = Clean = Replace Reference

* To be done by Factory Authorized Service Agent
Every Section 5-7,
8 8-8
Hours

 Coolant Level  Fuel Level  Oil Level  Oil, Fuel Spills

Every
50
Hours

 Weld Terminals
Every Section 8-4
100
Hours

 Battery Terminals  Air Cleaner Hoses  Air Cleaner Element

Every NOTICE − Change engine Engine
250 1/2 in.
(13 mm) oil and filter after initial 50 to Manual,
Hours 75 hours of use. Section 8-5,
8-8

Unreadable Labels  Fan Belt Tension  Oil  Oil Filter Spark Arrestor
Every
500
Hours

 Weld Cables  Fuel Filter  Inline Fuel Filter Radiator Thermostat

Every Section 5-7,
FUEL
1000 8-3, 8-6,
OR
Hours 8-8, and
Engine
SLUDGE Manual
Radiator Fluid Level  Inside Unit Valve Clearance*  Drain Sludge

 Slip Rings*
 Brushes*
Every
2000
Hours

 Injectors*

OM-4435 Page 40
8-3. Checking Generator Brushes

! Stop engine and let cool.

1 Generator Brush Assembly
Mark and disconnect leads at brush hold-
er assembly. Remove assembly. Press
on brush to be sure springs compress.
Replace assembly if brushes are dam-
aged or if brush material is at or near mini-
mum length. Check length from brush-
1 holder surface.

New Length:
5/8 in. (16mm) Replace Assembly if
Brushes are Damaged
Minimum Length:
1/4 in. (6.5mm)

GenBrush2 2012-05 / Ref 205 725

8-4. Servicing Air Cleaner

4 Keep nozzle
1 2 3
2 in. (51 mm)
from element.

Optional
5
Blow Inspect
aircleaner1 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 226 386-B

! Stop engine. ling an optional safety element to pro- Wipe off cap and housing. Remove cap
vide additional engine protection. and dump out dust. Remove element(s).
NOTICE − Do not run engine without air
Never clean a safety element. Re- Wipe dust from inside cap and housing
cleaner or with dirty element. Engine dam-
place the safety element after servic- with damp cloth. Reinstall safety element
age caused by using a damaged element
ing the primary element three times. (if present). Reinstall cap.
is not covered by the warranty.
Clean or replace primary element if dirty NOTICE − Do not clean housing with air
 The air cleaner primary element can (see note above before cleaning). Re- hose.
be cleaned but the dirt holding capac- place primary element if damaged. Re-
ity of the filter is reduced with each place primary element yearly or after six Clean primary element with compressed
cleaning. The chance of dirt reaching cleanings. air only.
the clean side of the filter while clean-
1 Housing
ing and the possibility of filter damage Air pressure must not exceed 100 psi (690
makes cleaning a risk. Consider the 2 Safety Element (Optional) kPa). Use 1/8 in. (3 mm) nozzle and keep
risk of unwarrantable equipment dam- nozzle at least 2 in. (51 mm) from inside of
3 Primary Element
age when determining whether to element. Replace primary element if it has
clean or replace the primary element. 4 Dust Cap holes or damaged gaskets.
5 Dust Ejector
If you decide to clean the primary ele- Reinstall primary element and cap (dust
ment, we strongly recommend instal- To clean air filter: ejector down).

OM-4435 Page 41
8-5. Inspecting And Cleaning Spark Arrestor Muffler

! Stop engine and let cool.

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

Tools Needed:
3/8 in.

803 582-F / Ref. 287 125-A

8-6. Servicing Engine Cooling System

! Stop engine and let cool.

1 Radiator Draincock
2 Radiator Cap Cover
Change coolant according to engine
manual. Add coolant according to Sec-
tion 5-7.
Run engine until engine reaches normal
operating temperature. Check coolant
level in recovery tank. Add coolant if nec-
essary.
After engine cools, check coolant level
again and add coolant if necessary.
2

804 009−F / Ref 287 125-A

OM-4435 Page 42
8-7. Adjusting Engine Speed On Standard Models

! Stop engine and let cool.

Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine
Engine Speed speed with tachometer or frequen-
(No Load) RPM (Hz) cy meter. See table for proper no
load speed. If necessary, adjust
speed as follows:
1880 (61.7)
Weld/Power Start engine and run until warm.
Maximum
Turn Process/Contactor switch to
Weld Terminals Always On − Stick
position.
1 Lock Nut
2 Adjustment Screw
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.

 Do not set engine speed higher

than specified. Tampering with
adjustments other than shown
may affect engine warranty
! Stop engine.
Close door.

Tools Needed:

803 563

OM-4435 Page 43
8-8. Servicing Fuel And Lubrication Systems

! Stop engine and let cool.

! After servicing, start engine
and check for fuel leaks.
Stop engine, tighten connec-
tions as necessary, and wipe
up spilled fuel.
1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary (Canister) Fuel Filter
5 Secondary (In-Line) Fuel
Filter
6 Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve
through hole in base. See engine
manual and engine maintenance
label for oil/filter change in-
formation.
To replace primary (canister) fuel
filter:
Turn filter counterclockwise. Re-
move filter.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new fil-
ter. Install new filter and turn clock-
wise.
Inspect fuel lines, and replace if
cracked or worn.
To drain water from fuel system:
2
See engine manual.
6 To replace secondary (in-line)
fuel filter:
Note direction of fuel flow as indi-
cated by arrow on side of filter. Re-
move fuel line clamps and discon-
nect fuel lines from fuel filter. Re-
place filter, reconnect fuel lines, and
4 reinstall clamps.
3 To drain sludge from fuel tank:
! Beware of fire. Do not smoke
and keep sparks and flames
away from drained fuel. Dis-
pose of drained fuel in an en-
vironmentally-safe manner.
Do not leave unit unattended
while draining fuel tank.
! Properly lift unit and secure
5 in a level position. Use ade-
quate blocks or stands to
support unit while draining
fuel tank.
Attach 1/2 ID hose to drain valve.
Put metal container under drain,
and use screwdriver to open
sludge drain valve. Close valve
when sludge has drained. Remove
hose.
Close door.
Tools Needed:

1
Ref 287 125-A / 804 009−C

OM-4435 Page 44
8-9. Overload Protection

! Stop engine.

 When a circuit breaker, supple-

mentary protector, or fuse
opens, it usually indicates a
more serious problem exists.
Contact Factory Authorized
Service Agent.
1 Fuse F1
F1 protects the stator exciter wind-
ing from overload. If F1 opens, weld
and generator power is low or stops
entirely.
2 Circuit Breaker CB1 (Not
Shown)
3 Supplementary Protector CB2
4 Supplementary Protector CB3

1 5 Supplementary Protector CB8

CB1 protects the engine battery cir-
cuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
when the fault is corrected.
CB2 protects the engine wiring har-
ness. If CB2 opens, the engine will
not crank.
CB3 protects part of the weld control
wiring harness. If CB3 opens, weld
and generator power output stops.
CB8 protects the 24 volt AC output to
remote receptacle RC14. If CB8
3 opens, 24 volt output to RC14 stops.
6
Press button to reset supplementary
protector.
6 Circuit Breaker CB9
CB9 protects the throttle solenoid
4 against overload. If CB9 opens, the
engine does not automatically idle
down. Check the linkage and sole-
noid. CB9 automatically resets.

Ref. 287 125-A / 803 566 / 804 009-F

OM-4435 Page 45
8-10. Optional Voltmeter/Ammeter Help Displays
Use the Voltmeter/Ammeter help
displays to diagnose and correct
fault conditions.

 When a help code is displayed

normally weld output has
stopped but generator power
output may be okay.

 To reset help displays, stop

1 unit and then restart. See item
5 below to reset Help 25 dis-

HL.P 20
play.
1 Help 20 Display
Indicates a failure of meter display
2 module PC2, or the wiring between
PC2 and main control module PC1.
If this display is shown, have Facto-

HL.P 21 ry Authorized Service Agent check

PC1, PC2, and the wiring between
PC1 and PC2.
3 2 Help 21 Display
Indicates thermistor TH1 on the
main rectifier heat sink has failed.

HL.P 22 If this display is shown, have Facto-

ry Authorized Service Agent check
TH1, and the wiring between TH1
4
and PC1.
3 Help 22 Display

HL.P 23
Indicates the rectifier heat sink has
overheated. If this display is shown,
check generator cooling system
5 and/or reduce duty cycle. Keep en-
gine access door closed when run-
ning to maintain proper cooling air
flow past rectifier. Allow unit to cool

HL.P 25 before restarting. If problem contin-

ues, have Factory Authorized Ser-
vice Agent check unit.
4 Help 23 Display
Can indicate a complete loss of
generator excitation, auxiliary pow-
er output, and weld output or a fail-
ure of one of the rectifier output
SCRs. If generator output is lost,
see trouble “No generator power or
weld output.” in section 8-11B. If
generator output is okay, have Fac-
tory Authorized Service Agent
check the rectifier SCRs.
5 Help 25 Display
Indicates a remote device con-
nected to Remote Receptacle
RC14 may be faulty. Help 25 is also
displayed whenever a remote de-
vice has been connected to RC14
and then disconnected. Clear fault
by stopping and restarting the unit
or by turning Process/Contactor
switch to another position. If prob-
lem continues, have Factory Autho-
rized Service Agent check the re-
mote device, filter board PC6, and
main control module PC1.

Ref. 804 009-F

OM-4435 Page 46
8-11. Troubleshooting

 Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 8-10).

A. Welding

Trouble Remedy

No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at AC receptacles. On/Off Switch Required position and turn remote contactor on (see Section 6-3).

Reset supplementary protector CB8 (see Section 8-9). Check for faulty remote device connected to
RC14.

Check and secure connections to Remote Control receptacle RC14 (see Section 5-10).

Check Voltmeter/Ammeter help displays (see Section 8-10).

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

Reset supplementary protector CB3. (see Section 8-9).

Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service
Agent check the field excitation circuit.

Check Voltmeter/Ammeter help displays (see Section 8-10).

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

Erratic weld output. Check and tighten connections inside and outside unit.

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Have Factory Authorized Service Agent check brushes and slip rings.

High weld output. Have Factory Authorized Service Agent check main control module PC1 and hall device HD1.

Low weld output. Check engine speed, and adjust if necessary.

Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service
Agent check the rotor.

Low open-circuit voltage. Check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent check main control module PC1, field excitation circuit, and main
rectifier.

No remote fine amperage control. Repair or replace remote control device.

Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 5-10).

No 24 volt AC output at Remote recep- Reset supplementary protector CB8 (24 volt) (see Section 8-9).
tacle RC14.

OM-4435 Page 47
B. Standard Generator Power

Trouble Remedy
No generator power output at AC recep- Reset receptacle supplementary protectors (see Section 7-1).
tacles; weld output okay.

No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
Check fuse F1, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check field
excitation circuit.

Reset supplementary protector CB3 (see Section 8-9).

Check Voltmeter/Ammeter help displays (see Section 8-10).

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power AC re- Have Factory Authorized Service Agent check field excitation circuit.
ceptacles.

Low output at generator power AC re- Check engine speed, and adjust if necessary.
ceptacles.

Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service
Agent check the rotor.

C. Engine

Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.

Check battery connections and tighten if necessary.

Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-9).
Have Factory Authorized Service Agent check engine wiring harness and components.

Reset supplementary protector CB2 (see Section 8-9).

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check Engine Control switch S1, Fuel/Hour gauge FUEL/HM,
and control relay CR2.

Engine cranks but does not start. Check fuel level.

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

Have Factory Authorized Service Agent check control relay CR1, Fuel/Hour gauge FUEL/HM, fuel
solenoid FS1, and the fuel pump.

Air in fuel system. See engine manual.

Engine hard to start in cold weather. Use Preheat switch S4 (see Section 6-2).

Keep battery in good condition. Store battery in warm area off cold surface.

Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.

Use correct grade oil for cold weather (see Section 8-1).

Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow
plug.

Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 5-7 ).

Check fuel/hour meter for indication of shutdown.

Reset supplementary protector CB2 and/or clear fault causing circuit breaker CB1 to trip (see Section
8-9). Have Factory Authorized Service Agent check engine alternator, engine harness, fuel solenoid
FS1, and the fuel pump.

Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, inte-
grated rectifier SR2, fuel solenoid FS1, and the fuel pump.

See engine manual.

OM-4435 Page 48
 Trouble Remedy
Engine slowly stopped and cannot be Check fuel level.
restarted.

Check fuel/hour meter for indication of shutdown.

Check engine air and fuel filters (see Sections 8-4 and 8-8).

See engine manual.

Battery discharges between uses. Turn Engine Control switch off when unit is not running.

Clean top of battery with baking soda and water solution; rinse with clear water.

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months).

Engine idles, but does not come up to Have Factory Authorized Service Agent check fuel/hour meter FUEL/HM, and current transformer
weld speed (units with idle option only). CT1.

Check for obstructed throttle solenoid.

Engine does not run at idle speed Check for obstructed throttle solenoid.
(units with idle option only).

Circuit breaker CB9 may be open. CB9 automatically resets when fault is corrected (see Section 8-9).

Have Factory Authorized Service Agent check fuel/hour meter FUEL/HM, and control relay CR4.

Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 10).
wetstacking occurs.

Notes

OM-4435 Page 49
 SECTION 9 − ELECTRICAL DIAGRAMS

Figure 9-1. Circuit Diagram For Welding Generator

OM-4435 Page 50
 240 674-B

OM-4435 Page 51
 SECTION 10 − RUN-IN PROCEDURE
run_in1 2007−04

10-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts
weld output and do not exceed duty
cycle or equipment damage may
occur.
1 Welding Generator
2 Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
NOTICE − Do not idle engine longer
than necessary. Piston rings seat
faster if engine runs at weld/power
rpm, and the welding generator is
kept loaded during run-in.
1
2 Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for addition-
al engine run-in information.

OM-4435 Page 52
10-2. Run-In Procedure Using Load Bank
! Stop engine.
! Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
4 ! Keep exhaust and pipe away
from flammables.
2 NOTICE − Do not perform run-in
procedure at less than 20 volts weld
1 output and do not exceed duty
cycle or equipment damage may
occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe correct
polarity.
Start engine and run for several
3 minutes.
Set load bank switches and then
adjust generator A/V control so
load equals rated voltage and
current of generator (see name-
plate, rating label, or the specifi-
cations section in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.
! Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0683

OM-4435 Page 53
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
procedure at 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
1 output.
Turn Off grid.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connec-
tors (polarity is not important).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
3 5 shown, if not provided on generator.
Start engine and run for several
minutes.
Set grid switches and then ad-
just generator A/V control so
load equals rated voltage and
4 current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).
+ Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.
! Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0684

OM-4435 Page 54
 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 Generator Power Receptacles
− Neutral Bonded To Frame
2 3-Prong Plug From Case
1 Grounded Equipment
3 2-Prong Plug From Double
Insulated Equipment
 Be sure equipment has double
insulated symbol and/or word-
ing on it.
! Do not use 2-prong plug un-
less equipment is double in-
sulated.

2 3

OR

gen_pwr 2012−03 − ST-800 577

11-2. Grounding Generator To Truck Or Trailer Frame

1 2

GND/PE

800 652-D

! Always ground generator frame to 3 Metal Vehicle Frame frame. Always connect a ground
vehicle frame to prevent electric wire from the generator equipment
Connect cable from equipment ground grounding terminal to bare metal on
shock and static electricity hazards. terminal to metal vehicle frame. Use #8 the vehicle frame as shown.
! Also see AWS Safety & Health Fact AWG or larger insulated copper wire.
Sheet No. 29, Grounding of Portable
And Vehicle Mounted Welding Gen-  Electrically bond generator frame to ve- ! Use GFCI protection when operat-
erators. hicle frame by metal-to-metal contact. ing auxiliary equipment. If unit does
not have GFCI receptacles, use
1 Equipment Grounding Terminal (On ! Bed liners, shipping skids, and GFCI-protected extension cord. Do
Front Panel) some running gear insulate the not use GFCI receptacles to power
2 Grounding Cable (Not Supplied) welding generator from the vehicle life support equipment.

OM-4435 Page 55
11-3. Grounding When Supplying Building Systems
1 Equipment Grounding
Terminal
2 Grounding Cable
Use #8 AWG or larger insulated
1 2 copper wire.
GND/PE 3 Ground Device
 Use ground device as stated in
electrical codes.
! Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
! Also see AWS Safety &
2 3 Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.

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
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
3 (see Section 11-8).
VOLTS 115 3 Rating Data
2 AMPS 4.5
1 Hz 60 Rating shows volts and amperes, or
watts required to run equipment.
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.
3 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-4435 Page 56
11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Split Phase 1/8 HP 800 300
1/6 HP 1225 500
1/4 HP 1600 600
1/3 HP 2100 700
1/2 HP 3175 875
Capacitor Start-Induction Run 1/3 HP 2020 720
1/2 HP 3075 975
3/4 HP 4500 1400
1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000
5 HP 23300 6000
7-1/2 HP 35000 8000
10 HP 46700 10700
Fan Duty 1/8 HP 1000 400
1/6 HP 1400 550
1/4 HP 1850 650
1/3 HP 2400 800
1/2 HP 3500 1100

11-6. Approximate Power Requirements For Farm/Home Equipment

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

OM-4435 Page 57
11-7. Approximate Power Requirements For Contractor Equipment
Contractor Rating Starting Watts Running Watts
Hand Drill 1/4 in 350 350
3/8 in 400 400
1/2 in 600 600
Circular Saw 6-1/2 in 500 500
7-1/4 in 900 900
8-1/4 in 1400 1400
Table Saw 9 in 4500 1500
10 in 6300 1800
Band Saw 14 in 2500 1100
Bench Grinder 6 in 1720 720
8 in 3900 1400
10 in 5200 1600
Air Compressor 1/2 HP 3000 1000
1 HP 6000 1500
1-1/2 HP 8200 2200
2 HP 10500 2800
Electric Chain Saw 1-1/2 HP, 12 in 1100 1100
2 HP, 14 in 1100 1100
Electric Trimmer Standard 9 in 350 350
Heavy Duty 12 in 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in 400 400
Flood Lights HID 125 100
Metal Halide 313 250
Mercury 1000
Sodium 1400
Vapor 1250 1000
Submersible Pump 400 gph 600 200
Centrifugal Pump 900 gph 900 500
Floor Polisher 3/4 HP, 16 in 4500 1400
1 HP, 20 in 6100 1600
High Pressure Washer 1/2 HP 3150 950
3/4 HP 4500 1400
1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900
2-1/2 HP 1300 1300

OM-4435 Page 58
11-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

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

1 Motor Start Code

2 Running Amperage
3 Motor HP
4 Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
4 AC MOTOR find kVA/HP. If code is not listed,
2 multiply running amperage by six to
1 VOLTS 230 AMPS 2.5 find starting amperage.
3 CODE M Hz 60
Step 2: Find Motor HP and Volts.
HP 1/4 PHASE 1
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.

1 2 5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
2 supply.

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

OM-4435 Page 59
11-10. Typical Connections To Supply Standby Power

! Have only qualified persons

perform these connections
according to all applicable
codes and safety practices.
! Properly install, ground, and
1 2 3 4 operate this equipment ac-
Fused cording to its Owner’s Manu-
Utility Welding al and national, state, and lo-
Disconnect
Electrical Transfer Switch Generator cal codes.
Switch
Service Output
(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
2 Transfer Switch (Double-Throw)
Essential
Loads Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is re-
stored.
Install correct switch (customer-
supplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customer-
supplied) if required by electrical
code.
4 Welding Generator Output
Generator output voltage and wir-
ing must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low volt-
age and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the prem-
ises. If generator does not produce
enough output to meet all require-
ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 11-4).

OM-4435 Page 60
11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads

Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten-
sion cord. Do not use GFCI receptacles to power life support equipment.

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current
Load (Watts) 4 6 8 10 12 14
(Amperes)

5 600 350 (106) 225 (68) 137 (42) 100 (30)

7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)

10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)

15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)

20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)

25 3000 175 (53) 112 (34) 62 (19) 37 (11)

30 3600 150 (46) 87 (26) 50 (15) 37 (11)

35 4200 125 (38) 75 (23) 50 (15)

40 4800 112 (34) 62 (19) 37 (11)

45 5400 100 (30) 62 (19)

50 6000 87 (26) 50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten-
sion cord. Do not use GFCI receptacles to power life support equipment.

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current
Load (Watts) 4 6 8 10 12 14
(Amperes)

5 1200 700 (213) 450 (137) 225 (84) 200 (61)

7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)

10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)

15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)

20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)

25 6000 350 (107) 225 (69) 125 (38) 75 (23)

30 7000 300 (91) 175 (53) 100 (31) 75 (23)

35 8400 250 (76) 150 (46) 100 (31)

40 9600 225 (69) 125 (38) 75 (23)

45 10,800 200 (61) 125 (38)

50 12,000 175 (53) 100 (31)

*Conductor size is based on maximum 2% voltage drop

OM-4435 Page 61
 SECTION 12 − PARTS LIST
 Hardware is common and not
available unless listed.

Wiring harnesses are listed at

the end of parts section.

9 10 13
11
12
6

7 14 23
104 15
5
16 24
103
102
105 17 22
110 21 25
20
4-Fig.12-5 19

3
101
18
100 91
1 90 92
2-Fig.12-3 89
84

98
83
97-Fig.12-2 99
85 82

86
88 81
87

93
80
94

95

96

Figure 12-1. Main Assembly

OM-4435 Page 62
 30 31
28
42
27
32 41
29

40
26 35
34 39
33
38
110 37

69 68

43
70 67 36
66 45
65 44
78 71 64 50 51 52
61 63 46
77 48 49 46
79

47 53
72-Fig.12-4 62

76 54

73
55
75 55
74

804 012−K 1 / 804 012-K 2

OM-4435 Page 63
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-1. Main Assembly

. . . 1 . . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . Figure 12-3 . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 217070 . . Bracket, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . Figure 12-5 . . Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 181853 . . Insulator, Screw (For Rectifier Mtg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 5 . . . . . Z1 . . . . . 245553 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192303 . . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 232425 . . Bracket, Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . +243709 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . PC1 . . . . 250280 . . Module, Main Control/Scr Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . T1 . . . . . 232445 . . Xfmr, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 259211 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 213501 . . Bracket, Fuel Pump/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Fuel Filter Mtg. (Order Thru Engine Manufacturer) . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 217687 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 207721 . . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . *213858 . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 214753 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 213602 . . Gasket, Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 212621 . . Pipe, Exhaust Flexible Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 183314 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 21 . . . . . . . . . . . . . . 212604 . . Baffle, Air Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 226018 . . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 244508 . . Pipe, Exhaust Spark Arresstor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 088528 . . Spark Arretsor, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 244507 . . Pipe, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . +249656 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 27 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 222513 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 201851 . . Cover, Radiator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 214604 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 192041 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 213472 . . Keeper, Latch Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 213471 . . Bracket, Cover Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 36 . . . . . . . . . . . . . . 217387 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 213503 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . +212607 . . Shroud, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 244812 . . Radiator, W/14# Cap 1 Row Core 1.25 In Inlet/Outlet . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187120 . . . . Cap, Radiator Pressure 14 Lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 212603 . . Baffle, Air Upper Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . +243710 . . Upright, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 243711 . . Cover, Radiator Access ........................................ 1
. . . 43 . . . . . . . . . . . . . . 220295 . . Bracket, Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 190190 . . Tank, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 213502 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 4
. . . 47 . . . . . . . . . . . . . . 217698 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 176108 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 237382 . . Label, Diesel Engine Maintenance Cat C1.5 . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 199592 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . +213487 . . Door, Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OM-4435 Page 64
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-1. Main Assembly (Continued)

. . . 53 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 54 . . . . . . . . . . . . . . 087341 . . Bumper, Door 1.000 Od X .750 High Rbr 50 Duro W/O . . . . . . . . . . . . . . 2
. . . 55 . . . . . . . . . . . . . . 243708 . . Panel, Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 213266 . . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 57 . . . . . . . . . . . . . . 197506 . . Screw, M14−1.5x 30 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 58 . . . . . . . . . . . . . . 213480 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 59 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 2
. . . 60 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Ft.
. . . 62 . . . . . . . . . . . . . . 176529 . . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197448 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 212612 . . Ftg, Adapter Oil Drain Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 212614 . . Hose, Radiator Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 217686 . . Belt, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . 237008 . . Engine, Cat Dsl Elec C1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦204136 . . Heater, Engine Block, 120V, 1000W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *202166 . . Filter, Oil Cat−150−4140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 217695 . . Switch, Coolant Temp N.C. 110c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . 212613 . . Hose, Radiator Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 216811 . . Clip, Nut Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 69 . . . . . . . . . . . . . . 249657 . . Air Cleaner, Intake 5.250 In (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249661 . . . . Dust Ejector, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦*197679 . . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249659 . . . . Cover Assy, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249658 . . . . Body, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197829 . . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 249664 . . . . Latch, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . 212617 . . Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . 217696 . . Switch, Lubricating Oil Pressure N.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . Figure 12-4 . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 213461 . . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 212623 . . Tank, Fuel (Includes Fuel Cap And Items Below) . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . 181572 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 212611 . . . . Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 212610 . . . . Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . SENDER . . 213265 . . . . Sender, Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 172071 . . Clamp, Hose .520 − .605 Clp Dia Slfttng Black . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . 134835 . . Hose, Sae .312 Id X .560 Od (order by foot) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 145054 . . Hose, Sae .187 Id X .410 Od X 26.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . . 213465 . . Bolt, J Stl .312−18 X 7.250 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 81 . . . . . . . . . . . . . . 213466 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . BATT . . . . 111352 . . Battery, Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 213668 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 85 . . . . . . . . . . . . . . 224266 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 86 . . . . . . . . . . . . . . 213458 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . . 213460 . . Crossmember, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . . 213463 . . Spacer/Snubber, Generator Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . . 213462 . . Pad, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . . 213459 . . Crossmember, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213670 . . Screw, 500−13x2.25 Hex Flange−hd Gr8 Pln Chem/Phys . . . . . . . . . . . . 2
OM-4435 Page 65
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-1. Main Assembly (Continued)

. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 213600 . . Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 213464 . . Bracket, Battery Locator (In Base − Not Shown) . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . . . 213485 . . Support, Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . . . 213483 . . Support, Engine Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . . 226150 . . Label, Ce Sound Power Level 96db . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . +226104 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . . 233952 . . Label, Warning General Precautionary (Wordless) . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . . . . . . . . . . 220955 . . Panel, Front Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . Figure 12-2 . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . CT1 . . ♦105370 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . . . . . . . . . . . Label, Rating Ce 907143 (CC Model) (Order By Model And Serial No.) . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . . . . . . . . . . . Label, Rating Ce 907281 (CC/CV Model) (Order By Model And Serial No.) . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . . 213504 . . Tray, Reactor&Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . TE1, TE2 . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 103 . . . . C11 . . . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . . . . . . . . . 214742 . . Capacitor Assy, (CC/CV Model) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213489 . . . . Bus Bar,Capacitor Bank Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213490 . . . . Bus Bar,Capacitor Bank Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . C10 . . . . 163535 . . . . Capacitor,Elctlt 16000 Uf 60 Vdc Can 1.75 Dia . . . . . . . . . . . . . . . . . . . . 6
. . 105 . . . . R3 . . . . . 213027 . . Resistor, WW Tap 300 W 40 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . ♦235023 . . Idle, Solenoid Assy (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . ♦234691 . . . . Bracket, Mtg Solenoid Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . TS1 . . ♦230634 . . . . Solenoid, Throttle W/4−8.4 Lb Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦198109 . . . . Screw, Shld Stl Sch .250−20 X .437 X .500 Shld . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . ♦235056 . . . . Linkage, Throttle Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 601868 . . . . Nut, 250−28 .44hex .26h Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . ♦234689 . . . . Arm, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 604224 . . . . Screw, 250−20x .75 Hexwhd.50d Stl Pld Slffmg Tap−rw . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 152461 . . . . Nut, 250−20 .44hex .23h Stl Pld Sem Cone Wshr.65d . . . . . . . . . . . . . . 3
. . 109 . . . . . . . . . . . . . 233088 . . Label, Danger Using A Generator Indoors Can Kill You In Minutes . . . . . 1
. . 110 . . . . . . . . . . . . . 285297 . . Adapter, Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 238650 . . Label, Hour/Fuel Meter Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 213506 . . Bracket, Hold−Down Fuel Tank (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 218460 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 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-4435 Page 66
 11
 Hardware is common and not
10 available unless listed.
12 Wiring harnesses are listed at
9 the end of parts section.
8

13 14 25
7 23 24
22
26 27
28
15
6 21

16
20 29
5

4
17
3
1 2 18
41
40 19
30
31
34 33 32
39

38
36 35
37

804 011−D

Figure 12-2. Panel, Front w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 97 )

... 1 . . . . . . . . . . . . . . 218764 . . Knob, Pointer 1.625 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . 206795 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . 207080 . . Knob, Pointer 1.125 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 ........................ Nameplate, Control (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . PC6 . . . . 229949 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . CB8 . . . . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . . 240672 . . Panel, Front Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . 214762 . . Bracket, Meter Hole Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . ♦214543 . . Enclosure, Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . ♦134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 4
... 12 . . . . PC2 . . ♦214660 . . Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . R1 . . . . . 214760 . . Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . . 1
... 14 . . . . . R2 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . S4 . . . . . 021467 . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . . 1

OM-4435 Page 67
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-2. Panel, Front w/Components (Continued)

. . . 16 . . . . . S1 . . . . . 217680 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 207073 . . Lever, Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201244 . . Washer, Tooth.728idx1.166odx.050t Stl Pld Int.688 . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 241432 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 010381 . . Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . C13, 14 . . . 128750 . . Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . RC12 . . . . 176355 . . Rcpt, Str 2p3w 16a 220v Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 206795 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 224428 . . Panel, Power CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . GFCI1 . . . 246865 . . Rcpt, Str Dx Grd 2p3w 20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . C11, 12 . . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . CB5 . . . . 093996 . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 1
. . . 27 . . . ELCB1 . . . 222991 . . Circuit Breaker, Elcb 16a 220v 0.030a Trip . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . ELCB2 . . . 222992 . . Circuit Breaker, Elcb 30a 220v 0.030a Trip . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 144844 . . Stand−off, No 6−32 X .875 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 4
. . . 30 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 32 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 33 . . . . RC11 . . . . 156831 . . Rcpt,Str 2p3w 32a 220v Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 34 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Weld Terminal (Order By Model & Serial No.) . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 37 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 39 . . . . . . . . . . . . . . 241433 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . FUEL/HM . . 232111 . . Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
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-4435 Page 68
 Hardware is common and not
available unless listed. 5
Wirng harnesses are listed at 4
the end of parts section.
3
2
6

1
8

10
11
12

13

14
803 689-E

Figure 12-3. Control Panel

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 12-3. Control Panel (Figure 12-1 Item 2)

... 1 . . . . . . . . . . . . . . 220981 .. Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . 129524 .. Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . 2
... 3 . . . . CR2 . . . . 252053 .. Relay, Encl 12vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . CB1 . . . . 190374 .. Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . CR1 . . . . 223710 .. Relay, Encl 12vdc Dpst−no 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . 046432 .. Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . F1 . . . . . 085874 .. Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . CR4 . . ♦090104 .. Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 1
... 9 . . . . CR3 . . . . 197325 .. Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . SR5, SR4 . . 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 11 . . . . SR3 . . ♦035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . SR2, SR1 . . 035704 .. Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 13 . . CB2, CB3 . . 083432 .. Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 2
... 14 . . . . CB9 . . ♦230635 .. Supplementary Pro, Auto Reset 1p 8a 12vdc Frict . . . . . . . . . . . . . . . . . . . 1
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
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-4435 Page 69
 Hardware is common and not
available unless listed.

Wiring harnesses are listed at 5

the end of parts section.
4 6
7
3
1

8
9

10
12

13

15
11

16
14

803 686-C

Figure 12-4. Generator

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

Figure 12-4. Generator (Figure 12-1 Item 71)

... 1 . . . ROTOR . . . 243820 . . Rotor, Generator 4 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 181143 . . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 192600 . . . . Fan, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 159918 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 212126 . . Adapter, Engine Machined Cat 3013c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 6
... 7 .............. 192686 . . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . 6
... 8 .............. 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 6
... 9 .............. 192686 . . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . 6
... 10 .............. 212641 . . Stud, Stl .375−16 1.625x 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 11 . . STATOR . . 251062 . . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 .............. 183336 . . Endbell (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 .............. 183419 . . . . O-Ring, 1.984 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 .............. 167788 . . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . 4
... 15 .............. 244290 . . Brushholder Assembly, Generator w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 .............. 136343 . . . . Screw, K50x 20 Pan Hd-phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . 2
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
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-4435 Page 70
 Hardware is common and not
available unless listed.
2
Wiring harnesses are listed at
the end of parts section. 1

4
5

804 010−A

Figure 12-5. Rectifier Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 12-5. Rectifier Assembly (Figure 12-1 Item 4)

.................... 217082 . . Rectifier, Assembly (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 1 .............. 211984 . . . . Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .............. 212601 . . . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . MOD1,2,3 . . 196760 . . . . Thyristor, Scr Module 190a 400v Dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 4 .............. 217085 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . C1−6 . . . . 215611 . . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 6 . . . . TH1 . . . . 213930 . . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead . . . . . . . . . . . . . . . . . 1
.................... 181853 . . Insulator, Screw (For Mounting Rectifier) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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.
 Some wiring harness components (switches, relays, circuit breakers) are also referenced elsewhere in this parts list. Purchase components sepa-
rately or as part of the associated wiring harness.

OM-4435 Page 71
 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase compo-
nents separately or as part of the associated wiring harness.

Item Dia. Part

No. Mkgs. No. Description Quantity

Wiring Harnesses

.................... 235012 . . Harness, Engine (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . S4 . . . . . 021467 . . . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . 1
. . . . . SR1, SR2, SR3 035704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . CB1 . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB2, CB3 . . 083432 . . . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . 2
. . . . . . . . . . CR3 . . . . 197325 . . . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR2 . . . . 214876 .. Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 212116 . . . . Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 212117 . . . . Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG6 . . . . 214932 . . . . Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
.................... 147995 . . . . Conn, Rect Univ 039 Skt 22−18ga .094od Gold . . . . . . . . . . . . . . . . . . . 7
.................... 177859 . . . . Conn, Body 5 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 129524 . . . . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . 2

.................... 235018 . . Harness, Weld Control (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG2 . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 214951 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal . . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 214934 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 235021 . . . . Connector, w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 193184 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG7 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . . 113750 . . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1
.................... 217000 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . 215340 . . . . Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S . . . . . . . . . . . . . 1
.................... 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . SR4, SR5 . . 035704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

.................... 214984 . . Harness, Rectifier Cc/Cv (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . PLG11 . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 207716 . . . . Conn, Faston Mini Polarized 2 Skt G1k1 . . . . . . . . . . . . . . . . . . . . . . . . . 6
.................... 207718 . . . . Conn, Faston Mini Polarized 2 Skt G2k2 . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . 217010 . . Harness, Receptacle Auxiliary Power (Includes) . . . . . . . . . . . . . . . . . . 1

. . . . . . . . CB4, CB6 . . 093996 . . . . Supplementary Pro, Man Reset 1p 20a 250vac Fric . . . . . . . . . . . . . . . . 2

OM-4435 Page 72
 Effective January 1, 2012
(Equipment with a serial number preface of MC or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions 6. 90 Days — Parts
Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its * Accessory (Kits)
1-800-4-A-MILLER original retail purchaser that new Miller equipment sold after the
effective date of this limited warranty is free of defects in material
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
for your local and workmanship at the time it is shipped by Miller. THIS
Non-Electronic Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
Miller distributor. WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * M-Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS. * MIG Guns and Subarc (SAW) Guns
Within the warranty periods listed below, Miller will repair or replace * Remote Controls and RFCS-RJ45
any warranted parts or components that fail due to such defects in * Replacement Parts (No labor)
Your distributor also gives * Roughneck Guns
material or workmanship. Miller must be notified in writing within
you ... thirty (30) days of such defect or failure, at which time Miller will * Spoolmate Spoolguns
Service provide instructions on the warranty claim procedures to be Miller’s True Blue® Limited Warranty shall not apply to:
You always get the fast, followed.
1. Consumable components; such as contact tips,
reliable response you Miller shall honor warranty claims on warranted equipment listed cutting nozzles, contactors, brushes, relays, work
need. Most replacement below in the event of such a failure within the warranty time station table tops and welding curtains, or parts that
parts can be in your periods. All warranty time periods start on the delivery date of the fail due to normal wear. (Exception: brushes and
equipment to the original end-user purchaser, and not to exceed
hands in 24 hours. relays are covered on all engine-driven products.)
one year after the equipment is shipped to a North American
Support distributor or eighteen months after the equipment is shipped to an 2. Items furnished by Miller, but manufactured by others,
Need fast answers to the International distributor. such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
tough welding questions? 1. 5 Years Parts — 3 Years Labor
Contact your distributor. * Original Main Power Rectifiers Only to Include SCRs, 3. Equipment that has been modified by any party other than
Diodes, and Discrete Rectifier Modules Miller, or equipment that has been improperly installed,
The expertise of the
improperly operated or misused based upon industry
distributor and Miller is 2. 3 Years — Parts and Labor
standards, or equipment which has not had reasonable
there to help you, every * Engine Driven Welding Generators and necessary maintenance, or equipment which has
step of the way. (NOTE: Engines are Warranted Separately by the been used for operation outside of the specifications for
Engine Manufacturer.) the equipment.
* Inverter Power Sources (Unless Otherwise Stated)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Plasma Arc Cutting Power Sources
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
* Process Controllers TRAINED AND EXPERIENCED IN THE USE AND
* Semi-Automatic and Automatic Wire Feeders MAINTENANCE OF WELDING EQUIPMENT.
* Smith 30 Series Flowgauge and Flowmeter
In the event of a warranty claim covered by this warranty, the
Regulators (No Labor) exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Transformer/Rectifier Power Sources replacement; or, where authorized in writing by Miller in
* Water Coolant Systems (Integrated) appropriate cases, (3) the reasonable cost of repair or
3. 2 Years — Parts replacement at an authorized Miller service station; or (4) payment
* Auto-Darkening Helmet Lenses (No Labor) of or credit for the purchase price (less reasonable depreciation
based upon actual use) upon return of the goods at customer’s risk
4. 1 Year — Parts and Labor Unless Specified
and expense. Miller’s option of repair or replacement will be F.O.B.,
* Automatic Motion Devices Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized
* CoolBelt and CoolBand Blower Unit (No Labor) service facility as determined by Miller. Therefore no
* External Monitoring Equipment and Sensors compensation or reimbursement for transportation costs of any
* Field Options kind will be allowed.
(NOTE: Field options are covered for the remaining TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
warranty period of the product they are installed in, or PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
for a minimum of one year — whichever is greater.) REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Flowgauge and Flowmeter Regulators (No Labor) DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
* RFCS Foot Controls (Except RFCS-RJ45) CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Fume Extractors PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor) ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Induction Heating Power Sources, Coolers ANY IMPLIED WARRANTY, GUARANTY OR
(NOTE: Digital Recorders are Warranted REPRESENTATION AS TO PERFORMANCE, AND ANY
Separately by the Manufacturer.) REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
* Load Banks MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
* Motor Driven Guns (w/exception of Spoolmate CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
Spoolguns) ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
* PAPR Blower Unit (No Labor) FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
* Positioners and Controllers ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS
* Racks EXCLUDED AND DISCLAIMED BY MILLER.
* Running Gear/Trailers Some states in the U.S.A. do not allow limitations of how long an
* Spot Welders implied warranty lasts, or the exclusion of incidental, indirect,
* Subarc Wire Drive Assemblies special or consequential damages, so the above limitation or
* Water Coolant Systems (Non-Integrated) exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
* Weldcraft-Branded TIG Torches (No Labor)
state to state.
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
5. 6 Months — Parts to the extent that they may not be waived, the limitations and
* Batteries exclusions set out above may not apply. This Limited Warranty
* Bernard Guns (No Labor) provides specific legal rights, and other rights may be available,
* Tregaskiss Guns (No Labor) but may vary from province to province.
miller_warr 2012-01
 Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

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

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2012 Miller Electric Mfg. Co. 2012−01