Miller Electric Welding System Metro 250D User Manual

OM-402B

April 1997

Eff. w/Serial Number KH383240

Processes

Shielded Metal Arc

(Stick) Welding

Gas Tungsten Arc

(TIG) Welding

With Optional Equipment:

Flux Cored Arc Welding

Description

Engine Driven Welding Generator



Metro 250D

Visit our website at

www.MillerWelds.com

Download from Www.Somanuals.com. All Manuals Search And Download.



Metro 250D

Description

Features

CALIFORNIA

NEW! Warranty extended to 3 years (engine

warranted by engine manufacturer)

Versatile weld output for DC Stick and DC

TIG welding

Proposition 65

Warning

Diesel engine exhaust and

some of its constituents

are known to the State of

California to cause

Multiple patented innovations put the new Metro

250D constant current welder/generator on the

leading edge of engine-driven welding technology.

Combining advanced design and outstanding DC

stick and DC TIG characteristics, the Metro is an

ideal machine for on-site work in construction,

fabrication, repair, power generation, pipe welding,

and rental markets as well.

Stepless amperage control for precise heat

selection

Arc force control ensures a forceful arc for

tight fit-ups − prevents electrode sticking

cancer, birth defects, and

other reproductive harm.

Built-in Hot Start circuit for dependable arc

starting

Remote control receptacle permits remote

current and contactor control

Delivering 250 amps at 100% duty cycle (280

amps at 60%), the Metro has the muscle to

handle tough assignments with the spare power

needed for other equipment.

Panel includes hour meter and fuel gauge

Earth leakage protection for auxiliary power

receptacles

The Metro boasts an industrial, air-cooled,

two-cylinder diesel engine that delivers 10

kVA/kW of auxiliary power and runs for at least 16

hours on one tank of fuel. The low noise case

provides remarkably quiet operation, 99 LW(A) or

74 dB(A) at 23 ft (7 m), making the Metro 250D an

excellent machine for work in noise-restricted

locations.

Product features and specifications are

subject to change without notice

Engine

Deutz/Ruggerini RD 211 twin-cylinder diesel

engine, 23 HP at 3600 RPM

Processes

Air cooling eliminates radiators, belts,

thermostats, coolant hoses, and antifreeze

required in liquid-cooled engines

Stick (SMAW) Welding

Automatic idle for fuel economy and reduced

noise

TIG (GTAW) Welding

Automatic shutdown system protects against

low oil pressure

With Optional Equipment:

Large 12 gallon (45 L) fuel capacity

Flux Cored (FCAW) Welding

Two-year North American warranty from

engine manufacturer

Call

The following terms are used interchangeably in

this manual: TIG = GTAW, Stick = SMAW

1-800-4-A-

MILLER

for your local

Miller distri-

butor.

Table of Contents

Section

Page

1. Safety Precautions . . . . . . . . . . . . . . . . . . . . .

1. Consignes de sécurité . . . . . . . . . . . . . . . . .

2. Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Your distributor gives

you ...

Miller offers a Technical Manual

which provides more detailed

service and parts information for

your unit. To obtain a Technical

Manual, contact your local

distributor. Your distributor can also

supply you with Welding Process

Manuals such as SMAW, GTAW,

GMAW, and GMAW-P.

Service

3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 15

4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5. Operating the Welding Generator . . . . . . . 21

6. Operating Auxiliary Equipment . . . . . . . . . 23

7. Maintenance & Troubleshooting . . . . . . . . 24

8. Electrical Diagram . . . . . . . . . . . . . . . . . . . . . 34

9. Run-In Procedure . . . . . . . . . . . . . . . . . . . . . . 36

10. Auxiliary Power Guidelines . . . . . . . . . . . . 39

11. Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Options and Accessories

You always get the fast,

reliable response you

need. Most replacement

parts can be in your

hands in 24 hours.

Support

For practical information on welding,

process applications, and Miller

products, visit our website at

Need fast answers to the

tough welding questions?

Contact your distributor.

The expertise of the

distributor and Miller is

there to help you, every

step of the way.

www.millerwelds.com

Warranty

Download from Www.Somanuals.com. All Manuals Search And Download.

1. Safety Precautions − Read Before Using

1.1 Symbol Usage

OM-402B -4/97, safety_rom 4/97

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

Marks a special safety message.

“

”

;

1.2 Arc Welding Hazards

The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see

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

avoid the hazard. The safety information given below is only

a summary of the more complete safety information found in

the Safety Standards listed in Section 1.5. Read and follow all

Safety Standards.

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

or another electrode from a different machine.

Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

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

or worktable as near the weld as practical.

Only qualified persons should install, operate, maintain, and

repair this unit.

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

During operation, keep everybody, especially children, away.

ARC RAYS can burn eyes and skin.

ELECTRIC SHOCK can kill.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, the

wire, wire reel, drive roll housing, and all metal parts touching the

welding wire are electrically live. Incorrectly installed or improperly

groundedequipment is a hazard.

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

your face and eyes from arc rays and sparks when welding or

watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

Wear approved safety glasses with side shields under your

helmet.

Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant mate-

rial (wool and leather) and foot protection.

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

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

there is a danger of falling.

FUMES AND GASES can be hazardous.

Use AC output ONLY if required for the welding process.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

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

unit.

Keep your head out of the fumes. Do not breathe the fumes.

If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

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

Properly install and ground this equipment according to its

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

Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

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

cadmiumplated steel, unless the coating is removed from the weld

area, the area is well ventilated, and if necessary, while wearing an

air-suppliedrespirator. The coatings and any metals containing

these elements can give off toxic fumes if welded.

Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

groundedreceptacle outlet.

When making input connections, attach proper grounding conduc-

tor first − double-check connections.

Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

Turn off all equipment when not in use.

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

Do not drape cables over your body.

If earth grounding of the workpiece is required, ground it directly

with a separate cable − do not use work clamp or work cable.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

WELDING can cause fire or explosion.

HOT PARTS can cause severe burns.

Allow cooling period before maintaining.

Wear protective gloves and clothing when

working on a hot engine.

Do not touch hot engine parts or just-welded

parts bare-handed.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

NOISE can damage hearing.

Protect yourself and others from flying sparks and hot metal.

Do not weld where flying sparks can strike flammable material.

Noise from some processes or equipment can

damagehearing.

Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

Wear approved ear protection if noise level is

high.

Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

Watch for fire, and keep a fire extinguisher nearby.

MAGNETIC FIELDS can affect pacemakers.

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

cause fire on the hidden side.

Pacemaker wearers keep away.

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

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

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

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock and fire hazards.

CYLINDERS can explode if damaged.

Do not use welder to thaw frozen pipes.

Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

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

shirt, cuffless trousers, high shoes, and a cap.

Protect compressed gas cylinders from excessive heat, mechani-

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

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

from your person before doing any welding.

Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

FLYING METAL can injure eyes.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder − explosion will result.

Wear approved safety glasses with side

shields even under your welding helmet.

Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

Turn face away from valve outlet when opening cylinder valve.

BUILDUP OF GAS can injure or kill.

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

use or connected for use.

Shut off shielding gas supply when not in use.

Always ventilate confined spaces or use ap-

proved air-supplied respirator.

Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

1.3 Engine Hazards

STEAM AND HOT COOLANT can burn.

FUEL can cause fire or explosion.

If possible, check coolant level when engine is

cold to avoid scalding.

Stop engine and let it cool off before checking or

adding fuel.

If the engine is warm and checking is needed,

follow the next two statements.

Do not add fuel while smoking or if unit is near

any sparks or open flames.

Do not overfill tank − allow room for fuel to expand.

Do not spill fuel. If fuel is spilled, clean up before starting engine.

Dispose of rags in a fireproof container.

Wear safety glasses and gloves and put a rag over radiator cap.

Turn cap slightly and let pressure escape slowly before completely

removing cap.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

BATTERY ACID can BURN SKIN and

EYES.

MOVING PARTS can cause injury.

Keep away from fans, belts, and rotors.

Keep all doors, panels, covers, and guards

closed and securely in place.

Do not tip battery.

Replace damaged battery.

Flush eyes and skin immediately with water.

Stop engine before installing or connecting unit.

Have only qualified people remove guards or covers for maint-

enance and troubleshooting as necessary.

To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

ENGINE EXHAUST GASES can kill.

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

parts.

Use equipment outside in open, well-ventilated

areas.

Reinstall panels or guards and close doors when servicing is

finished and before starting engine.

If used in a closed area, vent engine exhaust

outside and away from any building air intakes.

Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

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

components.

ENGINE HEAT can cause fire.

Do not locate unit on, over, or near combustible

surfaces or flammables.

BATTERY EXPLOSION can BLIND.

Keep exhaust and exhaust pipes way from

flammables.

Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

EXHAUST SPARKS can cause fire.

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

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

Observe correct polarity (+ and −) on batteries.

Do not let engine exhaust sparks cause fire.

Use approved engine exhaust spark arrestor in

required areas − see applicable codes.

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

1.4 Additional Symbols for Installation, Operation, and Maintenance

FALLING UNIT can cause injury.

OVERUSE can cause OVERHEATING.

Use lifting eye to lift unit only, NOT running

gear, gas cylinders, trailer, or any other

accessories.

Use equipment of adequate capacity to lift and

support unit.

Allow cooling period; follow rated duty cycle.

Reduce current or reduce duty cycle before

starting to weld again.

Do not block or filter airflow to unit.

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

extend beyond opposite side of unit.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handling

boards or parts.

FLYING SPARKS can cause injury.

Use proper static-proof bags and boxes to

store, move, or ship PC boards.

Wear a face shield to protect eyes and face.

Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper

face, hand, and body protection.

TILTING OF TRAILER can cause injury.

Sparks can cause fires — keep flammables away.

Use tongue jack or blocks to support weight.

Properly install welding generator onto trailer

according to instructions supplied with trailer.

OVERHEATING can damage motors.

Turn off or unplug equipment before starting or

stopping engine.

READ INSTRUCTIONS.

Do not let low voltage and frequency caused by

low engine speed damage electric motors.

Use only genuine MILLER replacement parts.

Perform engine maintenance and service

according to this manual and the engine

manual.

Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle

where applicable.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

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

navigation, safety services, computers, and

communicationsequipment.

Have only qualified persons familiar with

electronic equipment perform this installation.

Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

Be sure all equipment in the welding area is

electromagneticallycompatible.

The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

To reduce possible interference, keep weld cables as short as

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

If notified by the FCC about interference, stop using the

equipmentat once.

Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

Have the installation regularly checked and maintained.

Be sure this welding machine is installed and grounded

according to this manual.

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

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1.5 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

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

from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

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

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-

dent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

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

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Recommended Safe Practices for the Preparation for Weldingand Cut-

ting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

Safe Practices For Occupation And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

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

tion Association, Batterymarch Park, Quincy, MA 02269.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1.6 EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

To reduce magnetic fields in the workplace, use the following

procedures:

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

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

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

The following is a quotation from the General Conclusions Section of the

U.S. Congress, Office of Technology Assessment, Biological Effects of

Power Frequency Electric & Magnetic Fields − Background Paper,

OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May

1989): “. . . there is now a very large volume of scientific findings based

on experiments at the cellular level and from studies with animals and

people which clearly establish that low frequency magnetic fields can

interact with, and produce changes in, biological systems. While most

of this work is of very high quality, the results are complex. Current

scientific understanding does not yet allow us to interpret the evidence

in a single coherent framework. Even more frustrating, it does not yet

allow us to draw definite conclusions about questions of possible risk

or to offer clear science-based advice on strategies to minimize or avoid

potentialrisks.”

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

operator as practical.

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

ble.

About Pacemakers:

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

then following the above procedures is recommended.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

1. Consignes de sécurité − lire avant utilisation

1.1 Signification des symboles

OM-402B - 4/97, safety_rom_fre 4/97

Signifie Mise en garde ! Soyez vigilant ! Cette procédure

présente des risques de danger ! Ceux-ci sont identifiés

par des symboles adjacents aux directives.

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des

Identifie un message de sécurité particulier.

risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN

MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles

et aux directives ci-dessous afin de connaître les mesures à prendre pour

éviter tout danger.

;

’

1.2 Dangers relatifs au soudage à l’arc

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

les pièces endommagées. Entretenir l’appareil conformément à ce

manuel.

Porter un harnais de sécurité quand on travaille en hauteur.

Maintenir solidement en place tous les panneaux et capots.

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

sent manuel pour attirer votre attention et identifier les risques de

danger. Lorsque vous voyez un symbole, soyez vigilant et suivez

les directives mentionnées afin d’éviter tout danger. Les consi-

gnes de sécurité présentées ci-après ne font que résumer

l’information contenue dans les normes de sécurité énumérées

à la section 1-5. Veuillez lire et respecter toutes ces normes

de sécurité.

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

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

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

avec tout objet métallique.

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

vent être confiés qu’à des personnes qualifiées.

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

ticulièrement les enfants.

LES RAYONS DE L’ARC peuvent pro-

voquer des brûlures dans les yeux et

sur la peau.

Le rayonnement de l’arc du procédé de soudage génère

des rayons visibles et invisibles intenses (ultraviolets et

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut

provoquer une électrocution ou des blessures graves.

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

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

internes de l’appareil sont également sous tension à ce

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la

peau. Des étincelles sont projetées pendant le soudage.

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

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

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

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

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

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

terre présentent un danger.

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

trop élevé.

Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de

l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

Ne jamais toucher les pièces électriques sous tension.

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

de trous.

Porter des vêtements de protection constitué dans une matière durable, ré-

sistant au feu (laine ou cuir) et une protection des pieds.

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

lants suffisamment grands pour empêcher le contact physique éventuel

avec la pièce ou la terre.

LES FUMÉES ET LES GAZ peuvent

être dangereux.

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

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

Se servir d’une source électrique àcourant électrique UNIQUEMENT si le

procédé de soudage le demande.

Le soudage génère des fumées et des gaz. Leur inhalation

peut être dangereux pour votre santé.

Si l’utilisation d’une source électrique àcourant électrique s’avère néces-

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

Eloigner votre tête des fumées. Ne pas respirer les fumées.

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

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

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

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

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

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

homologué.

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

tions du fabricant concernant les métaux, les consommables, les

revêtements, les nettoyants et les dégraisseurs.

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

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

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

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

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

présente aucun danger.

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

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

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

toxiques et irritants.

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

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

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

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

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

correctement mise à la terre.

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

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

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

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

endommagé − un câble dénudé peut provoquer une électrocution.

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

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

mal épissés.

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

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

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

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

tous les métaux renfermant ces éléments peuvent dégager des fumées

toxiques en cas de soudage.

Ne pas enrouler les câbles autour du corps.

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

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

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

une électrode provenant d’une autre machine.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

LE SOUDAGE peut provoquer un in-

cendie ou une explosion.

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

Prévoir une période de refroidissement avant d’effec-

tuer des travaux d’entretien.

Le soudage effectué sur des conteneurs fermés tels que

des réservoirs, tambours ou des conduites peut provoquer

leur éclatement. Des étincelles peuvent être projetées de

Porter des gants et des vêtements de protection pour

travailler sur un moteur chaud.

l’arc de soudure. La projection d’étincelles, des pièces chaudes et des

équipements chauds peut provoquer des incendies et des brûlures. Le contact

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

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

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

danger.

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

récemment soudées.

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

chaud.

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

substances inflammables.

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

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

des protections homologués.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affecter

l’ouïe.

Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

Des étincelles et des matériaux chauds du soudage peuvent facilement

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

ouvertures.

LES CHAMPS MAGNÉTIQUES peuvent

affecter les stimulateurs cardiaques.

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

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

clencher un incendie de l’autre côté.

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

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

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

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

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

mins inconnus éventuels en provoquant des risques d’électrocution et

d’incendie.

Porteurs de stimulateur cardiaque, restez à distance.

Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher

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

de soudage par points.

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

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

de ou couper le fil à la pointe de contact.

Si des BOUTEILLES sont endomma-

gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous

haute pression. Si une bouteille est endommagée, elle peut

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

ment partie du procédé de soudage, les manipuler avec

précaution.

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

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

chaussures hautes et un couvre chef.

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

qu’un allumeur au butane ou des allumettes.

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

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

arcs.

DES PARTICULES VOLANTES

peuvent blesser les yeux.

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

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

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

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

des étincelles et des particules métalliques vo-

Tenir les bouteilles éloignées des circuits de soudage ou autres circuits

électriques.

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

quent de projeter du laitier.

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

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

teille.

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

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

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

raccords convenables pour cette application spécifique; les maintenir ainsi

que les éléments associés en bon état.

LES ACCUMULATIONS DE GAZ ris-

quent de provoquer des blessures ou

même la mort.

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

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

ou de branchement de la bouteille.

Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

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

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

normes de sécurité.

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

rateur d’adduction d’air homologué.

1.3 Dangers existant en relation avec le moteur

LE CARBURANT MOTEUR peut pro-

voquer un incendie ou une explosion.

LA VAPEUR ET LE LIQUIDE DE

REFROIDISSEMENT CHAUD peuvent

provoquer des brûlures.

Arrêter le moteur avant de vérifier le niveau de carbu-

rant ou de faire le plein.

Il est préférable de vérifier le liquide de

refroidissement une fois le moteur refroidi pour éviter

de se brûler.

Ne pas faire le plein en fumant ou proche d’une sour-

ce d’étincelles ou d’une flamme nue.

Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son

expansion.

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

rant renversé avant de faire démarrer le moteur.

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

Mettre des lunettes de sécurité et des gants, placer un torchon sur le

bouchon du radiateur.

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

d’enlever le bouchon.

Jeter les chiffons dans un récipient ignifuge.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

DES ORGANES MOBILES peuvent

provoquer des blessures.

L’ACIDE DE LA BATTERIE peut pro-

voquer des brûlures dans les YEUX et

sur la PEAU.

Ne pas approcher les mains des ventilateurs, cour-

roies et autres pièces en mouvement.

Ne pas renverser la batterie.

Remplacer une batterie endommagée.

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

Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de

protection.

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

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

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

d’entretien et de dépannage.

LES GAZ D’ÈCHAPPEMENT DU

MOTEUR peuvent provoquer des

accidents mortels.

Pour empêcher tout démarrage accidentel pendant les travaux d’entre-

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

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

ganes mobiles.

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

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

moteur.

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

en route accidentelle du moteur.

Bloquer le volant moteur pour éviter sa rotation lors d’une intervention

sur le générateur.

Utiliser l’équipement à l’extérieur dans des zones ou-

vertes et bien ventilées.

En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappe-

ment du moteur vers l’extérieur à distance des entrées d’air dans les bâti-

ments.

LA CHALEUR DU MOTEUR peut pro-

voquer un incendie.

L’EXPLOSION DE LA BATTERIE peut

RENDRE AVEUGLE.

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

de surfaces inflammables.

Toujours porter une protection faciale, des gants en

caoutchouc et vêtements de protection lors d’une in-

tervention sur la batterie.

Tenir

distance les produits inflammables de

l’échappement.

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

batterie.

Eviter de provoquer des étincelles avec les outils en travaillant sur la

batterie.

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

hicules de démarrage rapide.

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

LES ÉTINCELLES À L’ÉCHAPPEMENT

peuvent provoquer un incendie.

Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

Utiliser uniquement un pare-étincelles approuvé −

voir codes en vigueur.

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

lieu.

1.4 Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance

LA CHUTE DE L’APPAREIL peut

blesser.

LE SURCHAUFFEMENT peut endom-

mager le moteur électrique.

Utiliser l’anneau de levage uniquement pour soulever

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

gaz, remorque, ou autres accessoires.

Utiliser un équipement de levage de capacité suffi-

sante pour lever l’appareil.

Arrêter ou déconnecter l’équipement avant de dé-

marrer ou d’arrêter le moteur.

Ne pas laisser tourner le moteur trop lentement sous

risque d’endommager le moteur électrique à cause

d’une tension et d’une fréquence trop faibles.

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

que les fourches sont suffisamment longues pour dépasser du côté

opposé de l’appareil.

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

lieu.

LES ÉTINCELLES VOLANTES ris-

quent de provoquer des blessures.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

Porter un écran facial pour protéger le visage et les

yeux.

Laisser l’équipement refroidir ; respecter le facteur de

marche nominal.

Réduire le courant ou le facteur de marche avant de

poursuivre le soudage.

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

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

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

du corps.

Les étincelles risquent de causer un incendie − éloigner toute substance

inflammable.

Ne pas obstruer les passages d’air du poste.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

LES

CHARGES

peuvent

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer

des interférences.

ÉLECTROSTATIQUES

endommager les circuits imprimés.

Établir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pièces.

Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipements

de radio−navigation et de communication, les

services de sécurité et les ordinateurs.

Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de

circuits imprimes.

Demander seulement à des personnes qualifiées familiarisées avec des

équipements électroniques de faire fonctionner l’installation.

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

fié les interférences résultant de l’installation.

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

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

Maintenir soigneusement fermés les portes et les panneaux des sources

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

utiliser une terre et et un blindage pour réduire les interférences

éventuelles.

UNE REMORQUE QUI BASCULE peut

entraîner des blessures.

Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.

Installer convenablement le poste sur la remorque

comme indiqué dans le manuel s’y rapportant.

LIRE LES INSTRUCTIONS.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

Utiliser uniquement des pièces de rechange

MILLER.

L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique

sensible tel que les ordinateurs et l’équipement com-

mandé par ordinateur tel que les robots.

Effecteur la maintenance et la mise en service

d’après le manuel et celui du moteur.

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

électromagnétiquement.

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

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

sible (ex. par terre).

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

tronique sensible.

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

ment à ce mode d’emploi.

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

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

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

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

1.5 Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-

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

de la Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent

of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Règles de sécurité en soudage, coupage et procédés connexes, norme

CSA W117.2, de l’Association canadienne de normalisation, vente de

normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

RecommendedSafe Practice for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, norme AWS

F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL

33126

Safe Practices For Occupation And Educational Eye And Face Protec-

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

1430 Broadway, New York, NY 10018.

NationalElectrical Code, NFPA Standard 70, de la National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1.6 Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme,

des champs magnétiques basse fréquence

Afin de réduire les champs électromagnétiques dans l’environnement

de travail, respecter les consignes suivantes :

Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

L’extrait suivant est tiré des conclusions générales du document intitulé

Biological Effects of Power Frequency Electric & Magnetic Fields −

Background Paper, OTA−BP−E−53 (Washington DC : U.S. Govern-

ment Printing Office, mai 1989), publié par le Office of Technology

Assessment du Congrès américain : «... il existe maintenant d’abon-

dantes données scientifiques compilées à la suite d’expériences sur la

cellule ou d’études sur des animaux et des humains, qui montrent clai-

rement que les champs électromagnétiques basse fréquence peuvent

avoir des effets sur l’organisme et même y produire des transforma-

tions. Même s’il s’agit de travaux de très grande qualité, les résultats

sont complexes. Cette démarche scientifique ne nous permet pas

d’établirun tableau d’ensemble cohérent. Pire encore, elle ne nous per-

met pas de tirer des conclusions finales concernant les risques

éventuels, ni d’offrir des conseils sur les mesures à prendre pour rédui-

re sinon éliminer les risques éventuels». (Traduction libre)

Mettre tous les câbles du côté opposé de l’opérateur.

Ne pas courber et ne pas entourer pas les câbles autour de

vous.

Garder le poste de soudage et les câbles le plus loin possible de

vous.

Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les consignes mentionnées précédemment font partie de celles desti-

nées aux personnes ayant recours à un stimulateur cardiaque. Veuillez

consulter votre médecin pour obtenir plus de détails.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

2. Definitions

2.1 Symbols and Definitions

Fast

Fast/Slow

(Run/Idle)

Stop Engine

Start Engine

Slow (Idle)

Fuel

(Run, Weld/Power)

Glow Plug

Remote 14

Temperature

Panel/Local

Engine Oil

Check Injectors/

Pump

Check Valve

Clearance

Battery (Engine)

Arc Force (DIG)

Volts

Amperes

Stick (SMAW)

TIG (GTAW)

Engine-Driven,

Read Operator’s

Manual

Single-Phase

Engine

Negative

Time

Circuit Breaker

Alternator With

Rectifier

Alternating Current

(AC)

Direct Current

(DC)

Positive

Certified/Trained

Mechanic

Protective Earth

(Ground)

Input

Rated No Load

Voltage (Average)

Conventional Load

Voltage

Rated Welding

Current

Output

U₀

U₂

I₂

Rated Load

Rated No Load

Speed

Rated Idle Speed

Three Phase

rpm

Duty Cycle

Speed

Current

Hours

Power

Single Phase

min⁻¹

Seconds

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

2.2 General Precautionary Label

3/96

A. Warning! Watch Out! There

are possible hazards as

shown by the symbols.

B. Become trained and read the

instructions before working on

the machine or welding.

Electric shock from welding

electrode or wiring can kill.

1.1 Wear dry insulating gloves. Do

not touch electrode with bare

hand. Do not wear wet or

damagedgloves.

1.2 Protect yourself from electric

shock by insulating yourself

from work and ground.

1.1

1.2

1.3

1.3 Do not work on unit if engine

is running. Stop engine first.

Breathing welding fumes can

be hazardous to your health.

2.1 Keep your head out of the

fumes.

2.2 Use forced ventilation or local

exhaust to remove the fumes.

2.1

3.1

4.1

2.2

2.3

2.3 Use ventilating fan to remove

fumes.

Welding sparks can cause

explosion or fire.

3.1 Keep flammables away from

welding. Do not weld near

flammables.

3.2 Welding sparks can cause

fires. Have a fire extinguisher

3.2

3.3

nearby,

and

have

watchperson ready to use it.

3.3 Do not weld on drums or any

closed containers.

Arc rays can burn eyes and

injure skin.

4.1 Wear hat and safety glasses.

Use ear protection and button

shirt collar. Use welding helmet

with correct shade of filter.

+ + +

Wear complete

protection.

body

6.1

6.3

6.2

Do not remove or paint over

(cover) the label.

Engine fuel plus flames or

sparks can cause fire.

+ =

6.1 Do not smoke while fueling or if

near fuel.

6.2 Stop engine before fueling.

6.3 Do not fuel a hot engine.

7.1

7.2

Engine exhaust gases can kill.

7.1 Vent exhaust outside.

7.2 Use unit outside.

S-176 105-A

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

2.3 Battery Charging Label

3/96

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Do not smoke and keep

matches and flames away from

battery.

Sparks can cause battery

gases to explode. Battery

explosion can blind and injure.

Wear a face shield.

Battery acid can burn skin. Do

not spill acid.

Read Owner’s Manual.

Wear rubber gloves.

Dead battery

+ −

−

Engine block

Fully charged battery

10 Do not connect last negative

cable to dead battery − connect

instead to engine block.

11 Jumper cables

−

observe

−

polarity and make connections

in numbered sequence shown.

−

12 Once dead battery is charged,

disconnect cables in sequence

shown.

S-176 108

2.4 Fan and Moving Parts Label

3/96

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Moving parts, such as fans,

rotors, and belts, can cut

fingers and hands and cause

injury. Keep away from moving

parts.

S-176 106

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

2.5 Hot Muffler Label

3/96

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Hot muffler and exhaust pipes

can cause severe burns. Do

not touch hot muffler or pipes.

S-176 230

2.6 Diesel Fuel Label

3/96

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Engine fuel plus flames or

sparks can cause fire.

Do not smoke while fueling or if

near fuel.

Stop engine before fueling.

Do not fuel a hot engine.

Use Diesel Fuel only.

DIESEL

S-176 103

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

2.7 Falling Equipment Label

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

3/96

Falling equipment can cause

serious injury and damage.

Use lifting eye to lift or move

unit

only.

Use

proper

equipmentwhen lifting.

Do not use lifting eye to lift and

support unit and trailer or other

heavy devices or accessories.

S-176 104

2.8 Activation Tag

Remove unit from shipping

crate. Remove Owner’s

Manual from unit. Follow

instructions to install muffler.

3/96

Read Owner’s Manual. Read

labels on unit.

Use Diesel Fuel only, and fill

fuel tank. Leave room for

expansion.

Check oil level. Add oil if

necessary.

Warning! Watch Out! There

are possible hazards as

shown by the symbols. During

the first 50 hours of operation,

do not exceed 225 amperes

of weld output or 7 kVA of

auxiliary power output.

DIESEL

API CD-MIL L 2104D,

SF/CD, CC/CD

2.4 qt (2.3 L)

Warning! Watch Out! There

are possible hazards as

shown by the symbols. Read

Owner’s Manual. Follow

instructions to activate

battery.

0 − 50 h Std

275A

10kVA

0 − 225A

0 − 7kVA

3 ∼ 50 Hz

S-176 107-A

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

2.9 Do Not Use Ether Label

3/96

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Ether will damage engine. Do

not use ether as a starting aid.

Read Owner’s Manual.

Use glow plugs for 10−25

seconds to aid starting in cold

weather.

10 − 25 s

S-176 109

2.10 Manufacturer’s Rating Label

METRO 250D

20A/21V

280A/31V

35%

60%

100%

250A

30V

280A

31V

U = 58V

20A/11V

280A/21V

35%

60%

280A

21V

100%

250A

20V

U = 58V

−1

n = 3600 min

−1

n = 3700 min

n = 2200 min

PROTECTION CLASS I

120/240V

10kVA

42A

1 ∼ 60 Hz

S-176 095-C

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

3. Specifications

3.1 Weld, Power, and Engine Specifications

Maximum

Open-Circuit

Voltage DC

Rated Welding Amperage

Auxiliary Power

Rating

Fuel

Capacity

Average Sound

Level

Engine

Output

Range

280 A, 31 V DC,

60% Duty Cycle

Deutz/Ruggerini

RD211 Air-Cooled,

Two-Cylinder, 23

HP Diesel Engine

Single-Phase,

10 kVA/kW, 42 A,

120/240 V, 60 Hz

11.8 US gal

(44.6 L)

74.5 dB(A) at

23 ft (7 m)

20 − 280

(Average)

250 A, 30 V DC,

100% Duty Cycle

3.2 Dimensions, Weights, and Operating Angles

Dimensions

Height

Width

Depth

41 in (1041 mm)

30 in (762 mm)

Do not exceed operating angles while run-

ning or engine damage will occur.

Do not move or operate unit where it could

tip.

54-1/2 in (1384 mm)

29 in (737 mm)

25°

36-3/4 in (933 mm)

9/16 in (14 mm) Dia.

25°

15°

Weight

4 Holes

angles 2/97 ST-158 938

960 lb (435 kg)

3.3 Volt-Ampere Curve

SA-180 261

The volt-ampere curve shows the

minimum and maximum voltage

and amperage output capabilities of

the welding generator. Curves of all

other settings fall between the

curves shown.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

3.4 Fuel Consumption

SA-180 263-A

3.5 Duty Cycle and Overheating

duty1 5/95 / SB-180 262

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

Exceeding duty cycle can

damage unit and void

warranty.

60% Duty Cycle At 280 Amperes

100% Duty Cycle At 250 Amperes

64MMiniuntuetsesWWeledlidnigng

64MMiinnuutteessRReessttiinngg

Continuous Welding

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

3.6 AC Auxiliary Power Curve

SA-180 260

The auxiliary power curve shows

the auxiliary power in amperes

available at the receptacles.

4. Installation

4.1 Installing Welding Generator

install1 1/97 − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

Generator Base

Movement

Airflow Clearance

Metal Vehicle Frame

Do not lift unit from end.

18 in

(460 mm)

18 in

Equipment Grounding

Terminal

Grounding Cable

(460 mm)

18 in

(460 mm)

Use #10 AWG or larger insulated

copper wire.

If unit does not have GFCI re-

ceptacles, use GFCI-

protected extension cord.

18 in

(460 mm)

18 in

(460 mm)

Grounding

Location

GND/PE

Electrically bond genera-

tor frame to vehicle frame

by metal-to-metal contact.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

4.2 Connecting Battery and Installing Exhaust Pipe

ST-801 079-A / Ref. ST-175 918-C

Stop engine.

Tools Needed:

7/16, 1/2 in

optional.

Connect negative (−)

cable last.

−

4.3 Engine Prestart Checks

Ref. ST-159 219-D

Check all fluids daily. Unit must be

cold and on a level surface. Oil may

be added at either oil fill.

Full

Engine stops if oil pressure is low.

Diesel

Heavy loading during first 50

hours will damage engine.

Keep load less than 225A

(weld) or 7 kVA (power) for

first 50 hours.

Exhaust Pipe

If unburned fuel and oil collect in ex-

haust pipe during run-in, see Sec-

tion 9.

Full

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

4.4 Connecting to Weld Output Terminals

Ref. ST-158 936-D / Ref. ST-175 918-C

Positive (+) Weld Output

Terminal

Tools Needed:

3/4 in

Negative (−) Weld Output

Terminal

For Direct Current Electrode Positi-

ve (DCEP), connect work cable to

Negative (−) terminal and electrode

cable (Stick) or torch cable (TIG) to

Positive (+) terminal.

For Direct Current Electrode Nega-

tive (DCEN), reverse cable con-

nections.

If unit has optional polarity switch,

connect work cable to Work

terminal and electrode or torch

cable to electrode terminal.

4.5

Selecting Weld Cable Sizes

Total Cable (Copper) Length in Weld Circuit Not Exceeding

150 ft

(45 m)

200 ft

(60 m)

250 ft

300 ft

350 ft

(105 m)

400 ft

(120 m)

100 ft (30 m) or Less

60 − 100% Duty

Welding

Amperes

(70 m)

(90 m)

10 − 60%

10 − 100% Duty Cycle

Duty Cycle

Cycle

100

150

200

250

300

350

400

1/0

3/0

1/0

3/0

1/0

2/0

1/0

2/0

3/0

4/0

2/0

3/0

4/0

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

2-2/0

2-3/0

2-4/0

1/0

2/0

4/0

2-2/0

2-3/0

1/0

2-2/0

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.

S-0007-D

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

4.6 Remote 14 Receptacle RC1 Information

Ref. ST-158 93

Socket*

Socket Information

24 volt ac with respect to socket G. Protected by circuit

breaker CB5.

Contact closure to A completes 24 volt ac contactor

control circuit.

Circuit common for 24 volt ac circuit.

0 to +10 volts dc output to remote control with respect

to socket D.

Remote control circuit common.

0 to +10 volts dc input command signal from remote

control with respect to socket D.

Chassis common.

*The remaining sockets are not used.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

5. Operating the Welding Generator

5.1 Front Panel Controls

Ref. ST-175 918-C

Heavy loading during first 50 hours

will damage engine. Keep load less

than 225A (weld) or 7 kVA (power) for

first 50 hours.

Do not weld or use ac receptacles

with switch in Idle position.

Arc Force (Dig) Control

Use control to automatically increase

amperage as arc length is decreased, to

assist in arc starts, and reduce the chance of

the electrode freezing in the puddle. Set at

minimumfor TIG welding.

To Start: move Idle Lock switch to Idle

position and Engine Control switch to Start

position. Release Engine Control switch

when engine starts. Do not crank engine if

engine is still turning. Move Idle Lock switch

to Run/Idle position after engine warms.

Engine Control Switch

Use switch to operate glow plug (optional −

see table), start engine, select speed, and

stop engine.

Amperage Control

Voltmeter (Optional)

To Stop: turn Engine Control switch to Stop

10 Ammeter (Optional)

11 Amperage Control Switch

In Run/Idle position, engine runs at idle

speed at no load, and weld/power speed

under load. In Run position, engine runs at

weld/power speed.

position.

Engine Hour Meter

Fuel Gauge

Use switch to select front panel or remote

amperagecontrol.

. Use Run position for HF-start TIG

welding, and to maintain weld/power

speed under light auxiliary power loads.

12 Output (Contactor) Control Switch

Engine Oil Pressure Light

Use switch to control remote contactor if

connected to remote 14 receptacle RC1.

Engine stops and light goes on if oil pressure

is too low.

Idle Lock Switch

Weld output terminals are energized

when Output (Contactor) Control

switch is On and engine is running.

Polarity Switch (Optional)

Use switch to lock engine in idle speed dur-

ing start-up (see table).

Use switch to change polarity of weld output.

Using Idle Lock Switch

2150

rpm

Using Glow

Plug

2150

rpm

0 s

⁷⁰°F (21°C)

32°F (0°C)

−4°F (−20°C)

10 s

20 s

2150 rpm

(No Load)

3700 rpm

(Load)

3700

rpm

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

5.2 Remote Amperage and Contactor Control

Ref. ST-158 936-D / Ref. ST-175 918-C

Weld output terminals are

energized when Output

(Contactor) Control switch is

On and engine is running.

Remote 14 Receptacle RC1

Connect optional remote control to

RC1 (see Section 4.6).

. Place Engine Control switch in

Run position for HF-start TIG

welding.

Min (20 A DC)

Max (100 A DC)

Set Control

Set Switches

Adjust Remote Control

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

6. Operating Auxiliary Equipment

6.1 Auxiliary Power Receptacles

ST-175 902 / S-180 259

put from each duplex receptacle is 1.8 and RC4 do not work. 120 volts may still be

. Place Engine Control switch in Run

position to maintain weld/power speed

under light auxiliary power loads.

kVA/kW.

present at RC3 and RC4.

RC3 and RC4 supply 60 Hz single-phase

power at weld/power speed. Maximum out-

put from RC3 or RC4 is 10 kVA/kW.

Ground Fault Circuit Interrupter GFCI1

GFCI1 provides ground fault protection for

the auxiliary power receptacles. If a ground

fault is detected, GFCI Reset button pops

out and the receptacles do not work. Check

for faulty tools plugged in receptacles. Press

button to reset.

. Press button to reset circuit breaker. If a

circuit breaker continues to open,

contact a Factory Authorized Service

Agent.

Combinedoutput of receptacles is limited to

10 kVA/kW output of generator. If maximum

output is exceeded, auxiliary equipment may

stop or not run properly.

120 V 15 A AC Duplex Receptacle

RC1

120 V 15 A AC Duplex Receptacle

RC2

120/240 V 42 A AC Straight

Receptacle RC3

120/240 V 42 A AC Twistlock

Receptacle RC4 (Optional)

Circuit Breakers CB1 And CB2

. At least once a month, run engine at

weld/powerspeed and press test button

to verify GFCI is working properly.

CB1 and CB2 protect RC1 and RC2 from

overload. If a circuit breaker opens, the

receptacle does not work.

Auxiliary Power While Welding Table

Circuit Breakers CB3 And CB4

. Auxiliary power available at ac

receptacles decreases as weld

amperageincreases.

CB3 and CB4 protect all the receptacles

from overload. If CB3 opens, RC1, RC3 and

power at weld/power speed. Maximum out- RC4 do not work. If CB4 opens, RC2, RC3

RC1 and RC2 supply 60 Hz single-phase

METRO 250D

1 ∼ 60 Hz

240 V

120 V

280 A

250 A

200 A

150 A

100 A

50 A

1.3 kVA

2.5 kVA

4.4 kVA

6.1 kVA

7.6 kVA

5.5 A

10.4 A

18.3 A

25.4 A

31.7 A

1.3 kVA

2.5 kVA

4.4 kVA

6.0 kVA

11.0 A

20.8 A

36.7 A

50.0 A

150 A

100 A

6.1 kVA

25.4 A

6.0 kVA

50.0 A

8.9 kVA

37.1 A

6.0 kVA

50.0 A

7.6 kVA

31.7 A

6.0 kVA

50.0 A

0 A

10.0 kVA

41.7 A

6.0 kVA

50.0 A

50 A

0 A

8.9 kVA

37.1 A

6.0 kVA

10.0 kVA

41.7 A

6.0 kVA

50.0 _SA_{-180 259-A}

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

7. Maintenance & Troubleshooting

7.1 Routine Maintenance

Stop engine before maintaining.

Recycle engine

fluids.

Label. Service engine more often if used in

severe conditions.

8 h

Wipe up spills.

Check fluid levels.

See Section 4.3.

50 h

Clean and

tighten weld

connections.

Clean air filter element.

See Section 7.5.

100 h

Change oil.

Clean and

Clean cooling

system.

See engine manual.

See Section 7.3

and maintenance

label.

tighten battery

connections.

See Section 4.2.

200 h

Change oil filter.

See Section 7.3

and maintenance

label.

Change fuel

filter. See

Section 7.4.

Change fuel

filter. See

Section 7.4.

Replace

unreadable

labels.

250 h

300 h

Check and clean

spark arrestor.

See Section 7.8.

Check valve

clearance.

See engine manual.

500 h

Repair or replace

cracked cables.

Test/time injectors.

See engine manual.

1000 h

Blow out or

vacuum inside.

During heavy service,

clean monthly.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

100 Hrs.

°C

+40

°F

+104

DEUTZ/RUGGERINI RD211 DIESEL ENGINE

+30

+20

+10

+86

+59

8 Hrs.

+32

-10

-15

-20

12 V

BCI 58

^{430 A @ 0}°F (-18°C)

−1

2200 min

API CD-MIL L 2104D, SF/CD, CC/CD

2.4 qt (2.3 L)

−1

3700 min

200 Hrs.

250 Hrs.

300 Hrs.

MILLER 065 604

Nelson 70098

Donaldson P10-2745

50 Hrs.

MILLER 066 702

Deutz 77-175-24

Deutz 77-644-39

DIN 51 601

Deutz 77-656-19

BS 2869: A1, A2

72° F (20° C)

0.006 in (0.15 mm)

ASTM D 975-81: 1-D, 2-D

VV-F 800C: DF-A, DF-1, DF-2

S t = .5%

DIESEL

MILLER 066 893

Deutz 77-175-19

MILLER 066 113

11.8 gal (44.6 l)

S-157 812-E

Download from Www.Somanuals.com. All Manuals Search And Download.

7.3 Changing Engine Oil and Oil Filter

Ref. ST-159 219-D / Ref. ST-159 215-E / Ref. ST-175 918-C / Ref. S-0842

Stop engine.

See engine manual for oil/filter

change procedure. Drain oil while

engine is warm.

Oil Fill Caps (Use Either Cap)

Oil Drain Valve

Close oil drain valve and cap

before adding oil and

running engine.

Oil Filter

Dipstick

Tools Needed:

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

7.4 Changing Fuel Filters

Ref. ST-159 215-E / Ref. ST-175 918-C

Stop engine and let cool.

Secondary Fuel Filter

Remove filter.

Apply thin film of oil to gasket on

new filter. Install filter.

Primary Fuel Filter

Fuel Line

Remove filter. Inspect all fuel lines

and replace if cracked or worn.

Install new filter and clamps. Wipe

up any spilled fuel.

Start engine, and check for fuel

leaks.

Stop engine.

Tighten connections as necessary.

Tools Needed:

7.5 Servicing Air Cleaner

Ref. ST-175 918-C / Ref. ST-159 219-D / Ref. S-0698-B

Stop engine.

Do not run engine without air

cleaner or with dirty element.

Use only high pulsation-type

replacement filter listed on

maintenance label or engine

damage may occur.

Dust Cap

Element

Housing

Dust Valve

To Clean air filter:

Wipe off cap and housing. Remove

cap and dump out dust. Remove

element. Reinstall cap to keep out

dust.

Do not clean housing with air

hose.

Clean element with compressed air

only. Keep nozzle at least 1 in (25

mm) from inside of element. Max. air

pressure: 30 psi (207 kPa). Do not

remove plastic fins. Replace ele-

ment and valve if damaged. Replace

element yearly or after six clean-

ings.

Blow

Inspect

Reinstall element and cap (cap ar-

rows pointing down).

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

7.6 Adjusting Engine Speed

Ref. ST-159 215-E

After tuning engine, check engine

speeds with a tachometer (see table

for no load speeds). If necessary,

adjust speeds as follows:

Start engine and run until warm.

3700 rpm

2200 rpm

Idle Speed Adjustment

Turn Engine Control switch to Run/

Idle position.

Idle Speed Lock Nut

Idle Speed Screw

Loosen nut. Turn screw until engine

runs at idle speed. Tighten nut.

Weld/Power Speed Adjustment

Turn Engine Control switch to Run

position.

Weld/Power Speed Lock Nut

Weld/Power Speed Screw

Loosen nut and back out screw.

Linkage Lock Nut

Linkage

3 in

(76 mm)

Loosen nut and turn linkage until

engine runs 50 rpm above specified

weld/power speed. Tighten linkage

lock nut.

Leave no

space

between

nuts.

11 10

Turn weld/power speed screw until

engine runs at weld/power speed.

Tighten nut.

Stop engine.

Shutdown Adjustment

. Shutdown mechanism normally

does not require adjustment un-

less tampered with.

Shutdown Linkage Lock Nuts

Shutdown Linkage Rod

Loosen nuts. Turn rod until

measurementbetween swivels is

3 in (76 mm). Tighten nuts.

Shutdown Lever Lock Nut

10 Shutdown Lever Adjust Nut

11 Shutdown Lever Screw

12 Shutdown Lever

Loosen nuts. Back screw out and

away from lever. Turn lever

clockwise until lever hits internal

stop. Tighten adjust nut until screw

hits lever, then tighten adjust nut

another 1-1/2 turns to bring lever off

internal stop. Tighten nuts.

Tools Needed:

5/16, 3/8, 7/16 in,

10 mm

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

7.7 Overload Protection

Ref. ST-159 215-E / Ref. ST-158 936-D / Ref. St-175 918-C

Stop engine. If checking

fuse, disconnect battery

negative (−) cable.

. Press button to reset circuit

breaker. If fuse or breaker

continues to open, contact

Factory Authorized Service

Agent.

Weld And Auxiliary Power

Circuits

Fuse F2

F2 protects battery excitation

circuit. If F2 opens, weld and auxil-

iary output stops.

Fuse F3

F3 protects generator excitation

circuit. If F3 opens, weld and auxil-

iary power output is low.

Replace any open fuses. Reinstall

panel before operating unit.

Remote Control Circuit

Circuit Breaker CB5

CB9

CB8

CB5 protects 24 volt ac output to

Remote 14 receptacle RC1. If CB5

opens, RC1 24 volt output stops.

Engine Control Circuit

Circuit Breakers CB6, CB7,

CB8, And CB9

CB6 protects fuel solenoid circuit. If

CB6 opens, the engine does not

start.

CB7

CB7 protects throttle solenoid

circuit. If CB7 opens, the engine

does not run at weld/power speed.

CB8 protects Engine Control

switch and wiring harness. If CB8

opens, the engine does not crank.

CB6

S-179 489

CB9 protects optional glow plug

system. If CB9 opens, the glow plug

does not work.

Tools Needed:

3/8 in

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

7.8 Servicing Optional Spark Arrestor

ST-801 154-B / Ref. ST-175 918-C

Stop engine and let cool.

Spark Arrestor

Cleanout Plug

Remove plug and remove any dirt

covering cleanout hole.

Exhaust Pipe

Start engine and run at idle speed to

blow out cleanout hole. If nothing

blows out of hole, briefly cover end

of exhaust pipe with fireproof

material.

Stop engine and let cool.

Reinstall cleanout plug.

Tools Needed:

3/8 in

7.9 Welding Troubleshooting

Trouble

Remedy

No weld output.

Low weld output.

High weld output.

Check control settings (see Section 5.1).

Check fuses F2 and F3, and replace if necessary (see Section 7.7).

Have Factory Authorized Service Agent check main rectifier and capacitor C5.

Check and secure connections to Remote 14 Receptacle RC1.

Place Output (Contactor) Control switch in On position, or place switch in Remote 14 position and

connect remote contactor to Remote 14 receptacle RC1 (See Section 5.1).

Have Factory Authorized Service Agent check brushes and slip rings, main rectifier, integrated

rectifier SR3, capacitor C5, and circuit boards PC1 and PC6.

Check control settings (see Section 5.1).

Check fuses F2 and F3, and replace if open (see Section 7.7).

Check engine speed, and adjust if necessary (see Section 7.6).

Tune engine according to engine manual.

Place Amperage Control switch in Panel position, or place switch in Remote 14 position and connect

remote amperage control to Remote 14 receptacle RC1.

Have Factory Authorized Service Agent check brushes and slip rings, main rectifier, integrated rectifi-

er SR3, capacitor C5, Amperage Control R4, and circuit board PC6.

Check engine speed, and adjust if necessary (see Section 7.6).

Have Factory Authorized Service Agent check main rectifier.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

Trouble

Erratic weld output.

Remedy

Clean and tighten weld output connections inside and outside unit.

Use dry, properly-stored electrodes.

Remove excessive coils from weld cables.

Be sure connection to work piece is clean and tight.

Have Factory Authorized Service Agent check brushes, slip rings, main rectifier, integrated rectifier

SR3, capacitor C5, and circuit board PC6.

No 24 volt ac output at Remote 14

receptacle RC1.

Reset circuit breaker CB5 (see Section 7.7).

7.10 Auxiliary Power Troubleshooting

Trouble

Remedy

No output at auxiliary power

receptacles.

Disconnect equipment from receptacles during start-up.

Reset circuit breakers (see Section 6).

Reset ground fault circuit interrupter GFCI1 (see Section 6).

Check fuses F2 and F3, and replace if necessary (see Section 7.7).

Check receptacles for continuity and proper connections. Replace receptacle(s) if necessary.

Have Factory Authorized Service Agent check brushes, slip rings, relay CR5, and relay CR6.

Check fuses F2 and F3, and replace if necessary (see Section 7.7).

Check engine speed, and adjust if necessary (see Section 7.6).

Tune-up engine according to engine manual.

Low output at receptacles.

Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR3.

Check engine speed, and adjust if necessary (see Section 7.6).

Check receptacle wiring and connections.

High output at receptacles.

Erratic output at receptacles.

Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR3.

7.11 Engine Troubleshooting

Trouble

Remedy

Engine does not crank.

Reset circuit breaker CB8 (see Section 7.7).

Check battery, and replace if necessary.

Check plug PLG8 connection.

Check Engine Control switch S1 and replace if necessary.

Check engine charging and starting systems according to engine service manual.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

Trouble

Remedy

Engine cranks but does not start.

Check fuel level (see Section 4.3).

Reset circuit breaker CB6 (see Section 7.7).

If equipped with glow plug (optional), reset circuit breaker CB9 (see Section 7.7).

Check Engine Control switch S1, and replace if necessary.

Check low oil pressure shutdown switch S2, and replace if necessary.

See engine manual.

Have Factory Authorized Service Agent check fuel solenoid, and fuel solenoid control module.

Check oil level. Engine stops if oil pressure gets too low (see Section 4.3).

Engine starts, but stops when Engine

Control switch is released.

High Or Low Engine Speed.

Check engine speed, and adjust if necessary (see Section 7.6).

Engine does not return to idle speed.

Have Factory Authorized Service Agent check throttle solenoid TS1, relay CR4, and idle control mod-

ule.

Engine idles but does not reach weld

speed.

Reset circuit breaker CB7 (see Section 7.7).

Move Idle Lock switch to Run/Idle position.

Have Factory Authorized Service Agent check throttle solenoid TS1, relay CR4, throttle solenoid

control module, and idle control module.

Engine uses oil during run-in period;

wetstacking occurs.

Dry engine (see Section 9 and engine manual).

Battery discharges between uses.

Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.

Periodically recharge battery (approximately every 3 months).

Check engine charging system according to engine service manual.

Check Engine Control switch S1, and replace if necessary.

Replace battery.

Engine stopped and cannot be

restarted.

Check fuel level (see Section 4.3).

Reset circuit breaker CB6 (see Section 7.7).

Reset circuit breaker CB8 (see Section 7.7).

Check oil level. Engine stops if oil pressure gets too low (see Section 4.3).

See engine manual.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

Notes

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

8. Electrical Diagram

8.1 Circuit Diagram for Welding Generator

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

SC-181 758

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

9. Run-In Procedure

9.1 Wetstacking

runin2 12/96

Heavy loading during first 50

hours will damage engine.

Keep load less than 225A

(weld) or 7 kVA (power) for

first 50 hours.

. Do not idle engine longer than

necessary. Piston rings seat

faster if engine runs at weld/

power rpm, and the welding

generatoris kept loaded during

run-in.

Welding Generator

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-402

Download from Www.Somanuals.com. All Manuals Search And Download.

9.2 Run-In Procedure Using Load Bank

S-0683

Stop engine.

Do not touch hot exhaust

pipe, engine parts, or load

bank/grid.

Keep exhaust and pipe away

from flammables.

Load Bank

Turn all load bank switches Off. If

needed, connect load bank to 115

volts ac wall receptacle or genera-

tor auxiliary power receptacle.

Welding Generator

Set Amperage control at min.

Weld Cables

Connect load bank to generator

weld output terminals using proper

size weld cables with correct

connectors. Observe

polarity.

correct

Start engine and run for several

minutes.

Set load bank switches and then

adjust Amperage control so load

and output are 180 A.

Check generator and load bank

meters after first five minutes then

every fifteen minutes to be sure

generatoris loaded properly.

ing run-in; add oil if needed.

After one hour (minimum), place

Amperagecontrol in minimum posi-

tion, then turn off load bank to

remove load. Run engine several

minutes at no load.

Stop engine and let cool.

Engine Exhaust Pipe

Repeat procedure if wetstacking is

present.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

9.3 Run-In Procedure Using Resistance Grid

S-0684

Stop engine.

Do not touch hot exhaust

pipe, engine parts, or load

bank/ grid.

Keep exhaust and pipe away

from flammables.

Resistance Grid

Use grid sized for generator rated

output.

Turn Off grid.

Welding Generator

Set Amperage control at min.

Weld Cables

Connect grid to generator weld

output terminals using proper size

weld cables with correct connec-

tors (polarity is not important).

Voltmeter

Clamp-On Ammeter

Connect voltmeter and ammeter as

shown, if not provided on generator.

Start engine and run for several

minutes.

Set grid switches and then adjust

Amperagecontrol so load and out-

put are 180 A.

Check generator and meters after

first five minutes then every fifteen

minutes to be sure generator is

loaded properly.

ing run-in; add oil if needed.

After one hour (minimum), place

Amperagecontrol in minimum posi-

tion, then shut down grid to remove

load. Run engine several minutes

at no load.

Stop engine and let cool.

Engine Exhaust Pipe

Repeat procedure if wetstacking is

present.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

10. Auxiliary Power Guidelines

10.1 Selecting Equipment

aux_pwr 12/96 − Ref. ST-159 730 / ST-800 577

Auxiliary Power Receptacles

− Neutral Bonded To Frame

3-Prong Plug From Case

Grounded Equipment

2-Prong Plug From Double

Insulated Equipment

Be sure equipment

has this symbol

and/or wording.

10.2 Grounding Generator to Truck or Trailer Frame

S-0854

Generator Base

Metal Vehicle Frame

Equipment Grounding

Terminal

Grounding Cable

Use #10 AWG or larger insulated

copper wire.

If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

GND/PE

Electrically bond generator

frame to vehicle frame by

metal-to-metalcontact.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

10.3 Grounding When Supplying Building Systems

ST-800 576-B

EquipmentGrounding

Terminal

GND/PE

Grounding Cable

Use #10 AWG or larger insulated

copper wire.

Ground Device

Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

Use ground device as stated

in electrical codes.

10.4 How Much Power Does Equipment Require?

S-0623

Resistive Load

A light bulb is a resistive load and

requires a constant amount of pow-

er.

VOLTS 115

AMPS 4.5

Hz 60

Non-Resistive Load

Equipmentwith a motor is a non-re-

sistive load and requires approxi-

mately six times more power while

starting the motor than when run-

ning (see Section 10.8).

Rating Data

Rating shows volts and amperes,

or watts required to run equipment.

AMPERES x VOLTS = WATTS

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

requirementin watts.

4.5 A x 115 V = 520 W

The load applied by the drill is 520 watts.

EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,

add the individual loads to calculate total load.

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

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

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

10.5 Approximate Power Requirements for Industrial Motors

Industrial Motors

Rating

1/8 HP

1/6 HP

1/4 HP

1/3 HP

1/2 HP

1/3 HP

1/2 HP

3/4 HP

1 HP

Starting Watts

800

Running Watts

300

Split Phase

1225

500

1600

600

2100

700

3175

875

Capacitor Start-Induction Run

2020

720

3075

975

4500

1400

1600

2200

2850

3900

6800

2000

6000

8000

10700

400

6100

1-1/2 HP

2 HP

8200

10550

15900

23300

8100

3 HP

5 HP

Capacitor Start-Capacitor Run

Fan Duty

1-1/2 HP

5 HP

23300

35000

46700

1000

7-1/2 HP

10 HP

1/8 HP

1/6 HP

1/4 HP

1/3 HP

1/2 HP

1400

550

1850

650

2400

800

3500

1100

10.6 Approximate Power Requirements for Farm/Home Equipment

Farm/HomeEquipment

Stock Tank De-Icer

Rating

Starting Watts

1000

Running Watts

1000

650

Grain Cleaner

1/4 HP

1/2 HP

3/4 HP

1650

Portable Conveyor

Grain Elevator

3400

1000

1400

1100

2800

720

4400

Milk Cooler

2900

Milker (Vacuum Pump)

FARM DUTY MOTORS

Std. (e.g. Conveyors,

Feed Augers, Air

Compressors)

2 HP

1/3 HP

1/2 HP

3/4 HP

1 HP

10500

1720

2575

975

4500

1400

1600

2200

2850

3900

6800

2000

6000

8000

10700

1000

950

6100

1-1/2 HP

2 HP

8200

10550

15900

23300

8100

3 HP

5 HP

High Torque (e.g. Barn

1-1/2 HP

5 HP

Cleaners, Silo Unloaders,

Silo Hoists, Bunk Feeders)

23300

35000

46700

3300

7-1/2 HP

10 HP

1/2 HP

500 PSI

550 PSI

700 PSI

3-1/2 cu. ft. Mixer

High Pressure 1.8 Gal/Min

Washer 2 gal/min

2 gal/min

3150

4500

1400

1600

800

6100

Refrigerator or Freezer

Shallow Well Pump

3100

1/3 HP

1/2 HP

1/3 HP

1/2 HP

2150

750

3100

1000

800

Sump Pump

2100

3200

1050

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

10.7 Approximate Power Requirements for Contractor Equipment

Contractor

Rating

1/4 in

Starting Watts

350

Running Watts

350

Hand Drill

3/8 in

400

1/2 in

600

Circular Saw

Table Saw

6-1/2 in

7-1/4 in

8-1/4 in

9 in

500

900

1400

4500

6300

2500

1720

3900

5200

3000

6000

8200

10500

1100

350

1400

1500

1800

1100

720

10 in

Band Saw

14 in

Bench Grinder

6 in

8 in

1400

1600

1000

1500

2200

2800

1100

350

10 in

Air Compressor

1/2 HP

1 HP

1-1/2 HP

2 HP

Electric Chain Saw

Electric Trimmer

Electric Cultivator

1-1/2 HP, 12 in

2 HP, 14 in

Standard 9 in

Heavy Duty 12 in

1/3 HP

500

2100

400

700

Elec. Hedge Trimmer

Flood Lights

18 in

400

HID

125

100

Metal Halide

Mercury

Sodium

Vapor

313

250

1000

1400

1250

600

1000

200

Submersible Pump

Centrifugal Pump

Floor Polisher

400 gph

900 gph

3/4 HP, 16 in

1 HP, 20 in

1/2 HP

900

500

4500

6100

3150

4500

6100

1900

900

1400

1600

950

High Pressure Washer

3/4 HP

1400

1600

700

1 HP

55 gal Drum Mixer

Wet & Dry Vac

1/4 HP

1.7 HP

900

2-1/2 HP

1300

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

10.8 Power Required to Start Motor

S-0624

Motor Start Code

Running Amperage

Motor HP

AC MOTOR

VOLTS 230 AMPS 2.5

Hz 60

PHASE 1

Motor Voltage

CODE

1/4

To find starting amperage:

Step 1: Find code and use table to

find kVA/HP. If code is not listed,

multiplyrunning amperage by six to

find starting amperage.

Step 2: Find Motor HP and Volts.

Step 3: Determine starting amper-

age (see example).

Welding generator amperage out-

put must be at least twice the

motor’s running amperage.

Single-Phase Induction Motor Starting Requirements

Motor Start

Code

KVA/HP

6.3

7.1

8.0

9.0

10.0

11.2

12.5

14.0

kVA/HP x HP x 1000

VOLTS

= STARTING AMPERAGE

EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4

HP motor with a motor start code of M.

Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2

11.2 x 1/4 x 1000

= 12.2 A

Starting the motor requires 12.2 amperes.

230

10.9 How Much Power Can Generator Supply?

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

Limit Load To 90% Of

Generator Output

Always start non-resistive (motor)

loads in order from largest to small-

est, and add resistive loads last.

5 Second Rule

If motor does not start within 5

seconds, turn off power to prevent

motor damage. Motor requires

more power than generator can

supply.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

10.10 Typical Connections to Supply Standby Power

S-0405-A

generator is to supply standby power during

emergenciesor power outages.

Power Company Service

Meter

240 V

Main and Branch Overcurrent

Protection

120/240 Volt

Double-Pole, Double-Throw

Transfer Switch

120 V

60 Hz

Three-Wire

Service

120 V

Obtain and install correct switch.

Switch rating must be same as or

greater than the branch overcurrent

protection.

Circuit Breakers or Fused

Disconnect Switch

240 V

Obtain and install correct switch.

Extension Cord

Select as shown in Section 10.1 1.

Generator Connections

120 V

Load

120 V

Connect terminals or plug of ade-

quate amperage capacity to cord.

Follow all applicable codes and

safety practices.

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.

Load Connections

240 V

120/240 Volt

Single-Phase

Three-Wire

Generator Output

Connection

120 V

Ground

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

10.11 Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

Current

(Amperes)

Load (Watts)

600

350 (106)

250 (76)

175 (53)

112 (34)

87 (26)

62 (19)

50 (15)

37 (11)

225 (68)

150 (46)

112 (34)

75 (23)

50 (15)

37 (11)

137 (42)

100 (30)

62 (19)

37 (11)

30 (9)

100 (30)

62 (19)

50 (15)

30 (9)

840

400 (122)

275 (84)

175 (53)

137 (42)

112 (34)

87 (26)

1200

1800

2400

3000

3600

4200

4800

5400

6000

400 (122)

300 (91)

225 (68)

175 (53)

150 (46)

125 (38)

112 (34)

100 (30)

87 (26)

75 (23)

62 (19)

50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.

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

Current

(Amperes)

Load (Watts)

1200

1680

2400

3600

4800

6000

7000

8400

9600

10,800

12,000

700 (213)

500 (152)

350 (107)

225 (69)

175 (53)

125 (38)

100 (31)

75 (23)

450 (137)

300 (91)

225 (69)

150 (46)

100 (31)

75 (23)

225 (84)

200 (61)

125 (38)

75 (23)

200 (61)

125 (38)

100 (31)

60 (18)

800 (244)

550 (168)

350 (107)

275 (84)

225 (69)

175 (53)

150 (46)

125 (38)

100 (31)

800 (244)

600 (183)

450 (137)

350 (107)

300 (91)

250 (76)

225 (69)

200 (61)

175 (53)

60 (18)

75 (23)

*Conductor size is based on maximum 2% voltage drop

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

11. Parts List

11.1 Main Assembly

not available unless listed.

20 21

86 Fig 11-4

91 Fig 11-2

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

ST-801 488-A

Fig 11-3

Download from Www.Somanuals.com. All Manuals Search And Download.

OM-402

11.1 (Continued)

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

. . . 1 . . . . . . . . . . . . . . +163 828 . . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . 164 507 . . PANEL, side LH rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 171 053 . . SPRING, latch w/knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 3 . . . . . . . . . . . . . . +163 958 . . COVER, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 176 104 . . LABEL, warning falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . . . . . . . . . . . . 165 839 . . HINGE, concealed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 5 . . . . . . . . . . . . . . . 167 340 . . COVER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . . . . . . . . . 167 280 . . ANGLE, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . . . . . . . . . . . . 107 816 . . HOSE, SAE .250 ID x .500 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 2ft

. . . 8 . . . . . . . . . . . . . . . 172 295 . . GAS, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 172 297 . . BRACKET, flat mtg spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 172 296 . . BALL GAS SPRING, stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 9 . . . . . 3T . . . . . . 172 661 . . BLOCK, stud connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 173 734 . . LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 10 . . . . . . . . . . . . . . . 166 215 . . COVER, stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 004 214 . . BUSHING, snap-in nyl 1.625 ID x 2.000mtg hole . . . . . . . . . . . . . . . . . . . 1

. . . 11 . . . . . R2 . . . . . . 128 862 . . RESISTOR, WW adj 375W 50 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 12 . . . . . . . . . . . . . . . 166 214 . . COVER, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 13 . . . . . . . . . . . . . . . 165 840 . . FIREWALL, bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 162 451 . . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 14 . . . . Shunt . . . . . 030 080 . . SHUNT, meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 15 . . . . . . . . . . . . . . . 109 830 . . STAND-OFF, No. 8-32 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 16 . . . . PC6 . . . . . 132 495 . . CIRCUIT CARD, shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 17 . . . . . . . . . . . . . . . 162 636 . . UPRIGHT, base center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 18 . . . . . . . . . . . . . . . 157 026 . . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 19 . . . . . . . . . . . . . . . 172 133 . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 20 . . . . . . . . . . . . . . . 172 134 . . BOLT, J stl .250-20 x 9.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 21 . . . . . . . . . . . . . . . 167 677 . . BATTERY, stor 12V 430crk 75RSV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTORS, battery post . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 22 . . . . . . . . . . . . . . . 082 316 . . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 114 923 . . BOOT, insulator term post red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 23 . . . . . . . . . . . . . . . 179 964 . . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 24 . . . . . . . . . . . . . . . 164 871 . . TANK, fuel 12gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 172 373 . . . . SENDER, fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 172 371 . . . . FITTING, stand pipe hose .250 x 8.875 lg . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 172 372 . . . . FITTING, hose stl barbed M 1/4tbg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 25 . . . . . . . . . . . . . . . 171 348 . . HOSE ASSEMBLY, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 089 120 . . CLAMP, hose .375-.450 slfttng green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 084 173 . . CLAMP, hose .460-.545 slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

. . . 26 . . . . . . . . . . . . . . . 165 355 . . BRACKET, brace back RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 27 . . . . . . . . . . . . . . . 165 354 . . PAN, fuel splash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 176 103 . . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 28 . . . . . . . . . . . . . . . 107 343 . . GROMMET, rbr neck filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 29 . . . . . . . . . . . . . . . 015 603 . . CAP, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 30 . . . . . . . . . . . . . . . 166 723 . . ENCLOSURE, sides lower manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 31 . . . . . . . . . . . . . . . 166 638 . . ENCLOSURE, sides upper manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 32 . . . . . . . . . . . . . . . 164 552 . . BRACKET, brace back LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 176 109 . . LABEL, caution using either . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 33 . . . . . . . . . . . . . . . 166 634 . . DUCT, hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 34 . . . . . . . . . . . . . . . 144 802 . . PIPE, exhaust flexible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 179 646 . . GASKET, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 35 . . . . . . . . . . . . . . . 010 875 . . CLAMP, muffler 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 36 . . . . . . . . . . . . . . . 142 065 . . MUFFLER, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 37 . . . . . . . . . . . . . . . 162 448 . . UPRIGHT, base rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 38 . . . . . . . . . . . . . . . 164 318 . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 176 230 . . LABEL, hot exhaust parts do not touch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 39 . . . . . . . . . . . . . . . 109 591 . . CLAMP, muffler 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 40 . . . . . . . . . . . . . . . 603 767 . . CAP, weather No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

11.1 (Continued)

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

. . . 41 . . . . . . . . . . . . . . . 173 931 . . PIPE, exhaust elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 42 . . . . . . . . . . . . . . . 167 313 . . LATCH, elastic draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 43 . . . . . . . . . . . . . . . 166 722 . . BAFFLE, rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 44 . . . . . . . . . . . . . . . 173 366 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 45 . . . . . 4T . . . . . . 174 901 . . BLOCK, term 30A 6P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 46 . . . . . . . . . . . . . . . 178 913 . . SOLENOID, module control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . ♦043 138 . . COLD WEATHER DIESEL STARTING, (consisting of) . . . . . . . . . . . . . . 1

. . . . . . . . . . CB9 . . . . . 147 658 . . . . CIRCUIT BREAKER, man reset 1P 30A 250VAC . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . GP1 . . . . . 164 938 . . . . GLOW PLUG, 12V 65A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . CR7 . . . . . 155 309 . . . . CONTACTOR, solenoid 12VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 47 . . . . CB8 . . . . . 115 427 . . CIRCUIT BREAKER, man reset 1P 25A 250VAC . . . . . . . . . . . . . . . . . . 1

. . . 48 . . . . CB6,7 . . . . 083 432 . . CIRCUIT BREAKER, man reset 1P 10A 250VAC . . . . . . . . . . . . . . . . . . 2

. . . 49 . . . . . . . . . . . . . . . 175 897 . . LEVER, shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 50 . . . . . . . . . . . . . . . 170 438 . . SCREW, spot weld .250-20 x 3.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 51 . . . . . . . . . . . . . . . 127 648 . . CLEVIS, shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 52 . . . . . . . . . . . . . . . 172 375 . . LEVER, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 53 . . . . . . . . . . . . . . . 127 994 . . BALL JOINT, .250−20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 54 . . . . TS1 . . . . . 180 598 . . SOLENOID, throttle (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 180 751 . . . . WEAR BAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 55 . . . . . . . . . . . . . . . 172 374 . . BRACKET, mtg throttle solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 56 . . . . . . . . . . . . . . . Fig 11.3 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 57 . . . . . . . . . . . . . . . . . . . . . . . . . . HOSE, oil drain (included w/engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 58 . . . . . . . . . . . . . . . 099 542 . . CLAMP, hose .583-.688clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 59 . . . . . . . . . . . . . . . 176 166 . . FITTING, hose brs barbed fem 3/8tbg x 3/8NPT . . . . . . . . . . . . . . . . . . . 1

. . . 60 . . . . . . . . . . . . . . . 165 271 . . VALVE, oil drain 3/8-18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 61 . . . . . . . . . . . . . . . 176 244 . . SPRING CLIP, oil drain hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 62 . . . . . . . . . . . . . . . 107 816 . . HOSE, SAE .250 ID x .500 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 1ft

. . . 63 . . . . . . . . . . . . . . *066 113 . . FILTER, fuel inline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 64 . . . . . . . . . . . . . . . 177 975 . . GASKET, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 65 . . . . . . . . . . . . . . . 176 541 . . AIR CLEANER, intake (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . *065 604 . . . . AIR ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 66 . . . . . . . . . . . . . . . 010 862 . . CLAMP, hose 1.562-2.500clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 67 . . . . . . . . . . . . . . . 176 467 . . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 68 . . . . . . . . . . . . . . . 010 863 . . CLAMP, hose 1.125-3.000clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 69 . . . . . . . . . . . . . . . 154 639 . . HOUSING, blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 70 . . . . . . . . . . . . . . . 181 803 . . ENGINE, Deutz elec Ruggerini . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 71 . . . . . . . . . . . . . . . 166 094 . . MOUNT, engine vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 72 . . . . . . . . . . . . . . . 166 093 . . BRACKET, mtg engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 73 . . . . FS1 . . . . . 182 110 . . SOLENOID, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 74 . . . . . . . . . . . . . . . 166 724 . . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 75 . . . . . . . . . . . . . . . 175 893 . . LINKAGE, spherical rod end 1/4-28 LH female . . . . . . . . . . . . . . . . . . . . . 1

. . . 76 . . . . . . . . . . . . . . . 126 388 . . NUT, .250-28 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 77 . . . . . . . . . . . . . . . 172 392 . . LINKAGE, engine auto shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 78 . . . . . . . . . . . . . . . 175 894 . . LINKAGE, spherical rod end 10-32 female w/stud . . . . . . . . . . . . . . . . . . 1

. . . 79 . . . . . . . . . . . . . . . 166 726 . . BRACKET, mtg fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 80 . . . . . . . . . . . . . . . 166 635 . . ENCLOSURE, muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 81 . . . . . . . . . . . . . . *066 893 . . FILTER, fuel element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 82 . . . . . . . . . . . . . . . . . . . . . . . . . . BASE, fuel filter (see engine parts list) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 83 . . . . . . . . . . . . . . +166 952 . . BATTERY BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 176 108 . . LABEL, warning battery explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 84 . . . . . . . . . . . . . . +163 074 . . PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 176 106 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 85 . . . . . . . . . . . . . . +162 429 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 157 812 . . LABEL, engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 176 105 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, rating (48V optional receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 86 . . . . . . . . . . . . . . . Fig 11.4 . . CONTROL BOX w/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 87 . . . . PC1 . . . . . 182 891 . . CIRCUIT CARD, control main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

11.1 (Continued)

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

. . . 88 . . . . . . . . . . . . . . . 162 515 . . RECTIFIER, si diode (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . C1,3 . . . . . 048 420 . . . . CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . C2,4 . . . . . 106 641 . . . . CAPACITOR, cer disc .01uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . D1-3 . . . . . 037 957 . . . . DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . SCR1,2 . . . . 162 516 . . . . THYRISTOR, SCR 300A 300V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . 028 388 . . . . CLAMP, thyristor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 89 . . . . . . . . . . . . . . . 162 442 . . PANEL, air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 90 . . . . . . . . . . . . . . . 163 608 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 91 . . . . . . . . . . . . . . . Fig 11.2 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 92 . . . . . . . . . . . . . . . 164 126 . . TRIM, panel front bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 93 . . . . . . . . . . . . . . . 167 658 . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 94 . . . . PC5 . . . . . 148 608 . . CIRCUIT CARD, filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 141 690 . . GROMMET, scr No. 8/10 panel hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 95 . . . . PC7 . . . . . 181 261 . . CIRCUIT CARD, filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 96 . . . . . . . . . . . . . . . 162 447 . . UPRIGHT, base front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 172 804 . . HARNESS, wiring unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 182 032 . . HARNESS, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 172 802 . . HARNESS, receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 177 119 . . KIT, label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 137 180 . . CLAMP, stl cushion .875dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 166 347 . . TRIM, cover corners front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . 166 348 . . TRIM, cover corners rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . 168 071 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . 148 439 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . 158 720 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 165 688 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 168 847 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 168 809 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 164 899 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

♦Optional 043 139 Cold Weather Diesel Starting Kit.

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

11.2 Panel, Front w/Components (Fig 11.1 Item 91)

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

. . . 1 . . . . R4,5 . . . . . 072 623 . . POTENTIOMETER, CP plain rnd 1/T 2W 1K linear . . . . . . . . . . . . . . . . . 2

. . . 2 . . . . . S1 . . . . . . 172 070 . . SWITCH, ignition 5posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 3 . . . . . . . . . . . . . . . 178 772 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . . . . . . . . . . ♦169 331 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . . . . S6-8 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 6 . . . . RC3 . . . . . 132 539 . . RECEPTACLE, str 3P4W 50A 125/250V flush mtg . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . RC3 . . ♦♦173 423 . . RECEPTACLE, 3P 50A 125/250V twk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . CB3,4 . . . . 141 267 . . CIRCUIT BREAKER, man reset 1P 50A 250VAC . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, receptacle (order by model and serial number) . . . . . . . . . . . . . . 1

. . . 8 . . . RC1,2 . . . . 167 657 . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 9 . . . . CB1,2 . . . . 139 266 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . 2

. . . 10 . . . GFCI1 . . . . 172 072 . . SENSOR, GFCI Test & Reset 50A 240V . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 11 . . . . . . . . . . . . . . . 154 022 . . COVER, receptacle GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 12 . . . . PC2 . . . . . 147 554 . . CIRCUIT CARD, connector/receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

11.2 (Continued)

ST-801 515-A

not available unless listed.

21 20 19

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

. . . 13 . . . . CB5 . . . . . 083 432 . . CIRCUIT BREAKER, man reset 1P 10A 250VAC . . . . . . . . . . . . . . . . . . 1

. . . 14 . . . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 15 . . . . . . . . . . . . . . . 170 391 . . CONNECTOR, circ protective cap size 20 . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . . . . . . . . . . . 021 385 . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 17 . . . . . . . . . . . . . . . 082 788 . . HOLDER, light ind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 18 . . . . . PL1 . . . . *048 155 . . BULB, incand min 14V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 19 . . . . . . . . . . . . . . . 082 789 . . LENS, light ind red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 20 . . . . . FG . . . . . . 118 066 . . GAUGE, fuel elec 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . . . . . . . . . . ♦148 956 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 22 . . . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 23 . . . . . . . . . . . . . . . 072 590 . . LOCK, shaft pot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 24 . . . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 25 . . . . . . . . . . . . . . . 119 014 . . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 26 . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . 1

. . . 27 . . . . . HM . . . . . . 145 247 . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 28 . . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . ♦♦♦185 190 . . METER, amp dc 0−400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . ♦♦♦164 876 . . METER, volt dc 0−100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

♦Optional 042 924 Polarity Switch.

♦♦Optional 043 253 Receptacle Kit, 120/250V 50A twk.

*Recommended Spare Parts.

♦♦♦Optional 042 927 Meter Kit, volt and amp.

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-402

Download from Www.Somanuals.com. All Manuals Search And Download.

11.3 Generator (Fig 11.1 Item 56)

ST-801 289A

not available unless listed.

Item

No.

Part

No.

Description

Quantity

. . . 1 . . . . . . . . . . 166 770 . . STUD, stl .375-16 x 19.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . 160 943 . . ENDBELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 3 . . . . . . . . . . 166 727 . . ROTOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . . . . . . . 053 390 . . . BEARING, ball sgl row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . . . . . . . . . . 160 566 . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . . . +166 378 . . STATOR, generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . . . . . . . 172 656 . . GUARD, generator wire mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 8 . . . . . . . . . . 172 674 . . SPRING, ext . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 9 . . . . . . . . . . 165 850 . . ADAPTER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 10 . . . . . . . . . . 176 106 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 11 . . . . . . . . . . 170 861 . . STUD, stl .375-16 x 17.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 12 . . . . . . . . . . 125 548 . . HOLDER, brush elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 13 . . . . . . . . . . 005 614 . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 14 . . . . . . . . . *126 984 . . BRUSH w/SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 15 . . . . . . . . . . 161 306 . . CAP, brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 16 . . . . . . . . . . 047 879 . . BAR, retaining brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

11.4 Control Box w/Components (Fig 11.1 Item 86)

ST-801 288

not available unless listed.

15 14

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

. . . 1 . . . . D1,5 . . . 135 184 . . DIODE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 2 . . . . . . . . . . . . . 038 889 . . STUD, pri board brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

. . . . . . . . . . . . . . . . . . . 010 915 . . WASHER, flat brs .257 ID x .640 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

. . . . . . . . . . . . . . . . . . . 602 208 . . WASHER, tooth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

. . . . . . . . . . . . . . . . . . . 601 836 . . NUT, brs .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

. . . 3 . . . . . T1 . . . . 156 583 . . TRANSFORMER, control 42/36V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . SR2,3 . . 035 704 . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 5 . . . . . . . . . . . . . 083 147 . . GROMMET, scr No. 8/10 panel hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

. . . 6 . . . . . . . . . . . . . 026 947 . . STAND-OFF, insul .250-20 x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 7 . . . CR5,6 . . 174 596 . . RELAY, encl 110VDC DPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 8 . . . CR1,4 . . 173 069 . . RELAY, encl 12VDC SPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 9 . . . . . . . . . . . . . 171 345 . . TERMINAL BOARD, stator hook-up (consisting of) . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 172 449 . . . . BUS BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 10 . . . . . . . . . . . . . 166 719 . . MODULE, idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 11 . . . . . . . . . . . . . 098 376 . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 12 . . . . . F2 . . . . *073 426 . . FUSE, mintr gl slo-blo 5A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 13 . . . . . F3 . . . . *142 751 . . FUSE, mintr cer slo-blo 30A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 14 . . . . . . . . . . . . . . 087 111 . . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 15 . . . . . C1 . . . . . 087 110 . . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . 1T . . . . 038 772 . . BLOCK, term 20A 6P (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 601 219 . . . . LINK, jumper 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

Notes

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

Notes

Download from Www.Somanuals.com. All Manuals Search And Download.

Notes

OM-402

Download from Www.Somanuals.com. All Manuals Search And Download.

Notes

Download from Www.Somanuals.com. All Manuals Search And Download.

12. Options and Accessories

12.1 Metro 250D

WELD METERS − DC AMP & VOLT

3000-4AH FOUR-WHEEL TANDEM

TRAILER

NO. 84X FOUR-WHEEL TANDEM

TRAILER

(#042 947 Field)

Machine is prewired for easy installation of

field kit.

(#042 599)

(#042 150)

The tandem axle design enables this trailer

to ride smoothly over rough terrain. The unit

is equipped with fenders, lights, a leveling

jack, and safety chains. The two-wheel,

self-actuating hydraulic brake system

operates automatically as pressure is put

against the tongue of the trailer. Break-away

device automatically locks the brakes if the

trailer becomes loose. A hand-operated

parking brake is standard.

For off-the-road use only. The tandem axle

torsion bar design enables this trailer to ride

smoothly over rough terrain.

STARTING AID KITS

(#043 139 Field)

Improve starting in cold weather by adding

air intake manifold glow plug. Machine is

prewired.

SPARK ARRESTOR

(#042 915)

May be mandatory in some areas.

METRO RUNNING GEAR

(#042 941)

Note: Order hitch separately. When

ordering off-road trailers, the purchase

order must include the statement, “For

off-the-road use only.”

FENDER AND LIGHT KIT FOR NO. 84X

TRAILER

(#042 198)

NOte: Order hitch separately.

Includes fenders and 12 Volt light set.

TOOL BOX

(#040 638)

Easy-to-install running gear bolts onto Metro

base. Not for highway use. Includes axle,

wheels, fenders and tow bar.

HITCHES

CLEVIS (#042 151)

For use on No. 84X trailer. Shipping weight 5

kg (11 lbs.)

CLEVIS (#042 707)

(Not for highway use) For use with EDT

2400-2B trailer. Shipping weight 11 lbs. (5

kg)

50 mm (2 in.) BALL (#042 153)

For use with No. 84X and 3000-4AH trailers.

Shipping weight 5 lbs. (2 kg)

50 mm (2 in.) BALL (#042 705)

For use with EDT 2400-2B trailer. Shipping

weight 5 lbs. (2 kg)

76 mm (3 in.) LUNETTE EYE

(#042 152)

For use with No. 84X and 3000-4AH trailers.

Shipping weight 9 lbs. (4 kg)

64 mm (2-1/2 in.) LUNETTE EYE

(#042 706)

For use with EDT 2400-2B trailer. Shipping

weight 9 lbs. (4 kg)

For use with four-wheel trailers. Keeps tools

handy. Sturdy steel construction with hinged

cover. 5 in. (130 mm) divider in center of

box. Attachment hardware included. Height

11 in. (280 mm), depth 10 in. (254 mm),

length 44 in. (1120 mm).

LOCK UP KIT − FRONT PANEL

(#042 921)

Secures the front panel controls of the Metro

with a hinged metal panel. Includes key lock

for engine access cover.

CC-5 CANVAS COVER

(#040 144)

Heavy duty, blue, waterproof and mildew

resistant.

RHC-14 REMOTE HAND CONTROL

(#129 340)

Miniature hand control for remote current

and contactor control. Includes 20 ft. (6 m)

cord and 14-pin plug.

RFC-14 REMOTE FOOT CONTROL

(#129 339)

Heavy duty foot current and contactor

control. Includes 20 ft. (6 m) cord and 14-pin

plug.

EDT 2400-2B TWO-WHEEL TRAILER

(#042 895)

A 1089 kg (2400 lb.) capacity trailer has a

welded structural steel frame, heavy-duty

axle with roller bearing hubs and leaf spring

suspension. Mounting holes for all large

Miller engine driven welding generators are

prepunched. Mounting hardware provided.

Also included is a jack stand for raising and

lowering the tongue, safety chains, and

universal tongue mounting for optional

hitches. An optional fender and light kit is

required when trailer is used on the highway.

Note: Order hitch separately.

The EDT 2400-2B trailer and the No.

3000-4AH trailer, when equipped with

fender and light kit and 50 mm (2 in.) ball

hitch, conform to all applicable U.S.

Federal Motor Vehicle Safety Standards

in effect on date of manufacture.

VOLTAGE-SENSING WIRE FEEDER

SUPER S-32P COMPACT, PORTABLE

WIRE FEEDER

Literature Index No. M/6.26

For 0.23−5/64 in. (0.6−2.0 mm) hard and flux

cored wire.

FENDER AND LIGHT KIT FOR EDT

2400-2B TRAILER

(#042 896)

Includes fenders, 12 Volt lights, and

mounting hardware.

HF-251 SERIES

High Frequency Arc Starter and Stabilizer

(#042 388) HF-251D-1 115 Volt

(#042 387) HF-251-2 230 Volt

A portable 250 Amp unit for 50, 60, and 100

Hz input.

OM-303

Download from Www.Somanuals.com. All Manuals Search And Download.

Effective January 1, 2000

(Equipment with a serial number preface of “LA” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

Warranty Questions?

LIMITED WARRANTY − Subject to the terms and conditions

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

to its original retail purchaser that new Miller equipment sold

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

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

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.

APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches

Call

1-800-4-A-MILLER

for your local

Miller distributor.

Remote Controls

Accessory Kits

Replacement Parts (No labor)

Spoolmate 185 & Spoolmate 250

Canvas Covers

Within the warranty periods listed below, Miller will repair or

replace any warranted parts or components that fail due to

such defects in material or workmanship. Miller must be

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

failure, at which time Miller will provide instructions on the

warranty claim procedures to be followed.

Your distributor also gives

you ...

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

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings,

relays or parts that fail due to normal wear.

Service

You always get the fast,

reliable response you

need. Most replacement

parts can be in your

hands in 24 hours.

Miller shall honor warranty claims on warranted equipment

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

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

the equipment was delivered to the original retail purchaser, or

one year after the equipment is sent to a North American

distributor or eighteen months after the equipment is sent to an

International distributor.

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

such as engines or trade accessories. These items are

covered by the manufacturer’s warranty, if any.

Support

3. Equipment that has been modified by any party other

than Miller, or equipment that has been improperly

installed, improperly operated or misused based upon

industry standards, or equipment which has not had

reasonable and necessary maintenance, or equipment

which has been used for operation outside of the

specifications for the equipment.

Need fast answers to the

tough welding questions?

Contact your distributor.

The expertise of the

distributor and Miller is

there to help you, every

step of the way.

1. 5 Years Parts − 3 Years Labor

Original main power rectifiers

Inverters (input and output rectifiers only)

MILLER PRODUCTS ARE INTENDED FOR PURCHASE

AND USE BY COMMERCIAL/INDUSTRIAL USERS AND

PERSONS TRAINED AND EXPERIENCED IN THE USE

AND MAINTENANCE OF WELDING EQUIPMENT.

2. 3 Years — Parts and Labor

Transformer/Rectifier Power Sources

Plasma Arc Cutting Power Sources

Semi-Automatic and Automatic Wire Feeders

Inverter Power Supplies

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

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

replacement; or, where authorized in writing by Miller in

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

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

payment of or credit for the purchase price (less reasonable

depreciation based upon actual use) upon return of the goods

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

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

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

Miller. Therefore no compensation or reimbursement for

transportation costs of any kind will be allowed.

Intellitig

Engine Driven Welding Generators

(NOTE: Engines are warranted separately by

the engine manufacturer.)

3. 1 Year — Parts and Labor

DS-2 Wire Feeder

Motor Driven Guns (w/exception of Spoolmate

185 & Spoolmate 250)

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR

ANY OTHER LEGAL THEORY.

Process Controllers

Positioners and Controllers

Automatic Motion Devices

RFCS Foot Controls

Induction Heating Power Sources

Water Coolant Systems

HF Units

Grids

Maxstar 140

Spot Welders

Load Banks

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN

AND ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION OF LAW, CUSTOM OF TRADE OR COURSE

OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL

EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND

DISCLAIMED BY MILLER.

Miller Cyclomatic Equipment

Running Gear/Trailers

Plasma Cutting Torches (except APT & SAF

Models)

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

an implied warranty lasts, or the exclusion of incidental,

indirect, special or consequential damages, so the above

limitation or exclusion may not apply to you. This warranty

provides specific legal rights, and other rights may be

available, but may vary from state to state.

Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,

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

and exclusions set out above may not apply. This Limited

Warranty provides specific legal rights, and other rights may

be available, but may vary from province to province.

4. 6 Months — Batteries

5. 90 Days — Parts

MIG Guns/TIG Torches

Induction Heating Coils and Blankets

miller_warr 7/00

Download from Www.Somanuals.com. All Manuals Search And Download.

Owner’s Record

Please complete and retain with your personal records.

Model Name

Purchase Date

Distributor

Address

Serial/Style Number

(Date which equipment was delivered to original customer.)

City

State

Zip

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com

to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

Replacement Parts

Training (Schools, Videos, Books)

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

Welding Process Handbooks

www.MillerWelds.com

Contact the Delivering Carrier for:

File a claim for loss or damage during

shipment.

For assistance in filing or settling claims,

contact your distributor and/or equipment

manufacturer’s Transportation Department.

PRINTED IN USA

 2000 Miller Electric Mfg. Co. 6/00

Download from Www.Somanuals.com. All Manuals Search And Download.

Multitech Modem MT1432BA User Manual
Murphy Switch L1100 Series User Manual
Nlynx Switch Wireless Gateway User Manual
Olympus Microcassette Recorder VN 7600PC User Manual
One for All Stereo Amplifier SV 9540 User Manual
Opticon Scanner OPR 3001 User Manual
Oregon Scientific Thermometer RAR621 User Manual
Oregon Scientific Thermometer RMR232PHN User Manual
Panasonic Answering Machine KX F3500 User Manual
Panasonic Electric Shaver ES762 User Manual