OM-494
191 862P
January 2005
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Dual-OperatorEngine Driven Welding
Generator
Miller DU-OP
Visit our website at
Download from Www.Somanuals.com. All Manuals Search And Download.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-5. AC Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-7. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-2. Activating The Dry Charge Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-3. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-5. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-6. Safety Information For Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-7. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . . 19
5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . 20
5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . . 21
5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . 23
5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . 24
5-14. Making Single Operator CC Weld Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-15. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-16. Installing Ether Cylinder (Optional Ether Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-17. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-18. Remote 14 Receptacle Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-1. Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-2. Weld Controls (See Section 6-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-3. Weld Control Descriptions (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-1. 120 Volt And 240 Volt Duplex Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Download from Www.Somanuals.com. All Manuals Search And Download.
TABLE OF CONTENTS
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8-4. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8-6. Servicing Optional Ether Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8-7. Checking And Replacing Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-8. Resetting Fan Belt Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-9. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-10. Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
OPTIONS AND ACCESSORIES
WARRANTY
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_8/03
Y
Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
Y
Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
.
M
e
a
n
s
“
N
o
t
e
”
;
n
o
t
s
a
f
e
t
y
r
e
l
a
t
e
d
.
1-2. Arc Welding Hazards
D
Use only well-maintained equipment. Repair or replace damaged parts at
once. Maintain unit according to manual.
Y
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see the
symbol, watch out, and follow the related instructions to avoid the
hazard. The safety information given below is only a summary of
the more complete safety information found in the Safety Stan-
D
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece or work-
table as near the weld as practical.
Y
Y
Only qualified persons should install, operate, maintain, and re-
pair this unit.
D
D
Insulate work clamp when not connected to workpiece to prevent contact
with any metal object.
Do not connect more than one electrode or work cable to any single weld
output terminal.
During operation, keep everybody, especially children, away.
SIGNIFICANT DC VOLTAGE exists in inverters after stop-
ping engine.
ELECTRIC SHOCK can kill.
D
Stop engine on inverter and discharge input capacitors according to
instructions in Maintenance Section before touching any parts.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all metal
parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
D
D
D
Do not touch live electrical parts.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
Wear dry, hole-free insulating gloves and body protection.
If inside, ventilate the area and/or use exhaust at the arc to remove welding
fumes and gases.
Insulate yourself from work and ground using dry insulating mats or covers
big enough to prevent any physical contact with the work or ground.
D
D
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instructions for metals, consumables, coatings, cleaners, and degreasers.
D
Do not use AC output in damp areas, if movement is confined, or if there is a
danger of falling.
D
D
D
Use AC output ONLY if required for the welding process.
D
Work in a confined space only if it is well ventilated, or while wearing an air-
supplied respirator. Always have a trained watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury
or death. Be sure the breathing air is safe.
If AC output is required, use remote output control if present on unit.
Additionalsafety precautions are required when any of the following electri-
cally hazardous conditions are present: in damp locations or while wearing
wet clothing; on metal structures such as floors, gratings, or scaffolds;
when in cramped positions such as sitting, kneeling, or lying; or when there
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order present-
ed: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most
situations, use of a DC, constant voltage wire welder is recommended.
And, do not work alone!
D
D
Do not weld in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and
irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated
steel, unless the coating is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an air-supplied respirator. The
coatings and any metals containing these elements can give off toxic fumes
if welded.
D
Disconnect input power or stop engine before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
BUILDUP OF GAS can injure or kill.
D
D
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved
air-supplied respirator.
D
D
Properly install and ground this equipment according to its Owner’s Manual
and national, state, and local codes.
Always verify the supply ground — check and be sure that input power cord
ground wire is properly connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded receptacle outlet.
ARC RAYS can burn eyes and skin.
D
D
When making input connections, attach proper grounding conductor first −
double-check connections.
Arc rays from the welding process produce intense visible
and invisible (ultraviolet and infrared) rays that can burn eyes
and skin. Sparks fly off from the weld.
Frequently inspect input power cord for damage or bare wiring — replace
cord immediately if damaged — bare wiring can kill.
D
D
D
D
Turn off all equipment when not in use.
D
Wear a welding helmet fitted with a proper shade of filter to protect your face
and eyes from arc rays and sparks when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
D
D
Wear approved safety glasses with side shields under your helmet.
If earth grounding of the workpiece is required, ground it directly with a sep-
arate cable.
Use protective screens or barriers to protect others from flash and glare;
warn others not to watch the arc.
D
Do not touch electrode if you are in contact with the work, ground, or anoth-
er electrode from a different machine.
D
Wear protective clothing made from durable, flame-resistant material (wool
and leather) and foot protection.
OM-494 Page 1
Download from Www.Somanuals.com. All Manuals Search And Download.
WELDING can cause fire or explosion.
HOT PARTS can cause severe burns.
D
D
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.
D
D
D
D
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
NOISE can damage hearing.
Noise from some processes or equipment can damage
hearing.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not
possible, tightly cover them with approved covers.
D
Wear approved ear protection if noise level is high.
D
Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
MAGNETIC FIELDS can affect pacemakers.
D
D
Watch for fire, and keep a fire extinguisher nearby.
D
D
Pacemaker wearers keep away.
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause
fire on the hidden side.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
D
D
Do not weld on closed containers such as tanks, drums, or pipes, unless
they are properly prepared according to AWS F4.1 (see Safety Standards).
Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and
causing electric shock and fire hazards.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
normally part of the welding process, be sure to treat them
carefully.
D
D
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at contact tip
when not in use.
D
D
Protect compressed gas cylinders from excessive heat, mechanical
shocks, slag, open flames, sparks, and arcs.
D
D
D
Wear oil-free protective garments such as leather gloves, heavy shirt, cuf-
fless trousers, high shoes, and a cap.
Install cylinders in an upright position by securing to a stationary support or
cylinder rack to prevent falling or tipping.
Remove any combustibles, such as a butane lighter or matches, from your
person before doing any welding.
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
work and have a fire watcher and extinguisher nearby.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings de-
signed for the specific application; maintain them and associated parts in
good condition.
FLYING METAL can injure eyes.
D
Welding, chipping, wire brushing, and grinding cause
sparks and flying metal. As welds cool, they can
throw off slag.
D
D
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in use or
connected for use.
D
Wear approved safety glasses with side shields even
under your welding helmet.
D
Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
1-3. Engine Hazards
MOVING PARTS can cause injury.
BATTERY EXPLOSION can BLIND.
D
D
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
D
Always wear a face shield, rubber gloves, and protec-
tive clothing when working on a battery.
D
Stop engine before disconnecting or connecting bat-
tery cables or servicing battery.
D
Stop engine before installing or connecting unit.
D
D
D
D
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and −) on batteries.
D
Have only qualified people remove guards or covers for maintenance
and troubleshooting as necessary.
D
To prevent accidental starting during servicing, disconnect negative (−)
battery cable from battery.
Disconnect negative (−) cable first and connect it last.
D
D
Keep hands, hair, loose clothing, and tools away from moving parts.
Reinstall panels or guards and close doors when servicing is finished
and before starting engine.
FUEL can cause fire or explosion.
D
D
Before working on generator, remove spark plugs or injectors to keep
engine from kicking back or starting.
D
Stop engine and let it cool off before checking or add-
ing fuel.
D
Do not add fuel while smoking or if unit is near any
sparks or open flames.
Block flywheel so that it will not turn while working on generator compo-
nents.
D
D
D
D
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
OM-494 Page 2
Download from Www.Somanuals.com. All Manuals Search And Download.
BATTERY ACID can BURN SKIN and EYES.
STEAM AND HOT COOLANT can burn.
D
D
D
Do not tip battery.
Replace damaged battery.
D
If possible, check coolant level when engine is cold to
avoid scalding.
D
Always check coolant level at overflow tank, if pres-
ent on unit, instead of radiator (unless told otherwise
in maintenance section or engine manual).
Flush eyes and skin immediately with water.
D
If the engine is warm, checking is needed, and there is no overflow tank,
follow the next two statements.
ENGINE HEAT can cause fire.
D
D
Wear safety glasses and gloves and put a rag over radiator cap.
D
Do not locate unit on, over, or near combustible
surfaces or flammables.
Turn cap slightly and let pressure escape slowly before completely re-
moving cap.
D
Keep exhaust and exhaust pipes way from flam-
mables.
ENGINE EXHAUST GASES can kill.
EXHAUST SPARKS can cause fire.
D
Use equipment outside in open, well-ventilated ar-
eas.
D
D
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in re-
quired areas — see applicable codes.
D
If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
1-4. Compressed Air Hazards
BREATHING COMPRESSED AIR can
cause serious injury or death.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
D
D
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
D
D
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
COMPRESSED AIR can cause injury.
D
D
Do not touch hot compressor or air system parts.
Let system cool down before touching or servicing.
D
D
Wear approved safety goggles.
Do not direct air stream toward self or others.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
READ INSTRUCTIONS.
D
D
Read Owner’s Manual before using or servicing unit.
Stop engine and release air pressure before
servicing.
D
Release air pressure from tools and system before
servicing, adding or changing attachments, or open-
ing compressor oil drain or oil fill cap.
1-5. Additional Symbols For Installation, Operation, And Maintenance
OVERUSE can cause OVERHEATING.
FALLING UNIT can cause injury.
D
D
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before starting
to weld again.
D
D
D
Use lifting eye to lift unit only, NOT running gear, gas
cylinders, trailer, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
D
Do not block or filter airflow to unit.
OVERHEATING can damage motors.
STATIC (ESD) can damage PC boards.
D
Turn off or unplug equipment before starting or stop-
ping engine.
Do not let low voltage and frequency caused by low
engine speed damage electric motors.
D
Put on grounded wrist strap BEFORE handling
boards or parts.
D
D
Use proper static-proof bags and boxes to store,
move, or ship PC boards.
D
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where
applicable.
FLYING SPARKS can cause injury.
TILTING OF TRAILER can cause injury.
D
D
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with proper
guards in a safe location wearing proper face, hand,
and body protection.
D
D
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer accord-
ing to instructions supplied with trailer.
D
Sparks can cause fires — keep flammables away.
OM-494 Page 3
Download from Www.Somanuals.com. All Manuals Search And Download.
READ INSTRUCTIONS.
ARC WELDING can cause interference.
D
Use only genuine MILLER/Hobart replacement
parts.
D
Electromagnetic energy can interfere with sensitive
electronic equipment such as microprocessors,
computers, and computer-driven equipment such as
robots.
Be sure all equipment in the welding area is electro-
magnetically compatible.
D
Perform engine and air compressor (if applicable)
maintenance and service according to this manual
and the engine/air compressor (if applicable) manu-
als.
D
D
D
D
D
To reduce possible interference, keep weld cables as short as possible,
close together, and down low, such as on the floor.
H.F. RADIATION can cause interference.
Locate welding operation 100 meters from any sensitive electronic
equipment.
D
High-frequency (H.F.) can interfere with radio naviga-
tion, safety services, computers, and communica-
tions equipment.
Be sure this welding machine is installed and grounded according to this
manual.
D
Have only qualified persons familiar with electronic
equipment perform this installation.
If interference still occurs, the user must take extra measures such as
moving the welding machine, using shielded cables, using line filters, or
shielding the work area.
D
D
The user is responsible for having
a
qualified electrician
promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at
once.
D
D
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep spark
gaps at correct setting, and use grounding and shielding to minimize the
possibility of interference.
1-6. California Proposition 65 Warnings
Y
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Y
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1-7. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-
ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
in Toronto 416-747-4044, website: www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandards Association, Standards Sales, 178 Rexdale Bou-
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices—phone for Region 5, Chicago, is
312-353-2220,website: www.osha.gov).
1-8. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-494 Page 4
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 8/03
Y
A
v
e
r
t
i
s
s
e
m
e
n
t
:
P
r
o
t
é
g
e
z
v
o
u
s
e
t
l
e
s
a
u
t
r
e
s
d
e
s
b
l
e
s
s
u
r
e
s
−
l
i
s
e
z
e
t
s
u
i
v
e
z
c
e
s
p
r
é
c
a
u
t
i
o
n
s
.
2-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés par
des symboles adjacents aux directives.
Ce groupe de symboles si-
gnifie Mise en garde
Soyez vigilant ! Il y a des
risques de danger reliés
!
Y
Identifie un message de sécurité particulier.
aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux
PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-des-
sous afin de connaître les mesures à prendre pour éviter tout danger.
.
S
i
g
n
i
f
i
e
N
O
T
A
;
n
’
e
s
t
p
a
s
r
e
l
a
t
i
f
à
l
a
s
é
c
u
r
i
t
é
.
2-2. Dangers relatifs au soudage à l’arc
D
D
En effectuant les raccordements d’entrée fixer d’abord le conducteur de
mise à la terre approprié et contre-vérifier les connexions.
Y
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris-
ques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécu-
ces normes de sécurité.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas en-
dommagé ou dénudé − remplacer le cordon immédiatement s’il est
endommagé − un câble dénudé peut provoquer une électrocution.
D
D
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épissés.
D
D
Ne pas enrouler les câbles autour du corps.
Y
Y
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour.
D
D
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
une électrode provenant d’une autre machine.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
manuel.
UN CHOC ÉLECTRIQUE peut tuer.
D
D
D
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès
que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce
Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec
la pièce à souder ou la table de travail, le plus près possible de la soudure.
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact avec
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la
terre présentent un danger.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
D
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des compo-
sants.
D
D
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas
de trous.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
D
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens iso-
lants suffisamment grands pour empêcher le contact physique éventuel
avec la pièce ou la terre.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
D
D
D
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
D
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.
Si l’utilisation d’une source électrique àcourant électrique s’avère néces-
saire, se servir de la fonction de télécommande si l’appareil en est équipé.
À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
D
D
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
D
Des précautions de sécurité supplémentaires sont requises dans des envi-
ronnements à risque comme: les endroits humides ou lorsque l’on porte
des vêtements mouillés; sur des structures métalliques au sol, grillages et
échafaudages; dans des positions assises, à genoux et allongées; ou
quand il y a un risque important de contact accidentel avec la pièce ou le
sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence:
1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un
poste à souder manuel (électrode enrobée) DC, 3) un poste à souder ma-
nuel AC avec tension à vide réduite. Dans la plupart des cas, un poste
courant continu de type CV est recommandé. Et, ne pas travailler seul!
Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-
tions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D
Travailler dans un espace fermé seulement s’il est bien ventilé ou en por-
tant un respirateur à alimentation d’air. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des
blessures ou des accidents mortels. S’assurer que l’air de respiration ne
présente aucun danger.
D
D
Ne pas souder dans des endroits situés à proximité d’opérations de dé-
graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
D
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation,
à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D
D
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvani-
sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si néces-
saire, en portant un respirateur à alimentation d’air. Les revêtements et
tous les métaux renfermant ces éléments peuvent dégager des fumées
toxiques en cas de soudage.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre
du sectionneur ou que la fiche du cordon est raccordée à une prise
correctement mise à la terre.
OM-494 Page 5
Download from Www.Somanuals.com. All Manuals Search And Download.
D
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B
pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi-
mité.
LES ACCUMULATIONS DE GAZ ris-
quent de provoquer des blessures ou
même la mort.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
D
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques vo-
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
rateur d’adduction d’air homologué.
lantes. Pendant la période de refroidissement des soudures, elles ris-
quent de projeter du laitier.
LES RAYONS DE L’ARC peuvent pro-
voquer des brûlures dans les yeux et
sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets et
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
D
Prévoir une période de refroidissement avant d’effec-
tuer des travaux d’entretien.
D
Porter un casque de soudage muni d’un écran de filtre approprié pour pro-
téger votre visage et vos yeux pendant le soudage ou pour regarder (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D
Porter des gants et des vêtements de protection pour
travailler sur un moteur chaud.
D
Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
récemment soudées.
D
D
D
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de
l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
LE BRUIT peut affecter l’ouïe.
Porter des vêtements de protection constitué dans une matière durable, ré-
sistant au feu (laine ou cuir) et une protection des pieds.
Le bruit des processus et des équipements peut affecter
l’ouïe.
LE SOUDAGE peut provoquer un in-
cendie ou une explosion.
D
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Le soudage effectué sur des conteneurs fermés tels que
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles peuvent être projetées de
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
l’arc de soudure. La projection d’étincelles, des pièces chaudes et des
équipements chauds peut provoquer des incendies et des brûlures. Le contact
accidentel de l’électrode avec des objets métalliques peut provoquer des
étincelles, une explosion, un surchauffement ou un incendie. Avant de
commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
D
D
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.
D
D
D
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Si des BOUTEILLES sont endomma-
gées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normale-
ment partie du procédé de soudage, les manipuler avec
précaution.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
substances inflammables.
Déplacer toutes les substances inflammables à une distance de 10,7 m de
l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec
des protections homologués.
D
Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des
ouvertures.
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou
dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une bou-
teille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords convenables pour cette application spécifique; les maintenir ainsi
que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
les équipements associés et les publication P-1 CGA énumérées dans les
normes de sécurité.
D
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D
D
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-
clencher un incendie de l’autre côté.
D
D
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-
voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés
correctement conformément à AWS F4.1 (voir les normes de sécurité).
D
D
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.
D
D
D
D
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porte-électro-
de ou couper le fil à la pointe de contact.
D
D
D
D
Porter des vêtements de protection dépourvus d’huile tels que des gants
en cuir, une chemise en matériau lourd, des pantalons sans revers, des
chaussures hautes et un couvre chef.
D
Avant de souder, retirer toute substance combustible de vos poches telles
qu’un allumeur au butane ou des allumettes.
2-3. Dangers existant en relation avec le moteur
LES ACCUMULATIONS DE GAZ ris-
quent de provoquer des blessures ou
même la mort.
L’ACIDE DE LA BATTERIE peut pro-
voquer des brûlures dans les YEUX et
sur la PEAU.
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
D
D
D
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
rateur d’adduction d’air homologué.
OM-494 Page 6
Download from Www.Somanuals.com. All Manuals Search And Download.
D
D
D
D
D
Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,
L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.
débrancher le câble négatif (−) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga-
nes mobiles.
D
Toujours porter une protection faciale, des gants en
caoutchouc et vêtements de protection lors d’une in-
tervention sur la batterie.
Remettre en place les panneaux ou les dipositifs de protection et fermer les
portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en
route accidentelle du moteur.
D
D
D
Arrêter le moteur avant de débrancher ou de brancher les câbles de
batterie.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le
générateur.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhi-
cules de démarrage rapide.
D
D
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier
lieu.
D
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
LE CARBURANT MOTEUR peut pro-
voquer un incendie ou une explosion.
D
Toujours vérifier le niveau de liquide de refroidissement dans le vase d’ex-
pansion (si présent), et non dans le radiateur (sauf si précisé autrement
dans la section maintenance du manuel du moteur).
D
Arrêter le moteur avant de vérifier le niveau de carbu-
rant ou de faire le plein.
D
D
D
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme sui-
vant :
D
Ne pas faire le plein en fumant ou proche d’une sour-
ce d’étincelles ou d’une flamme nue.
Mettre des lunettes de sécurité et des gants, placer un torchon sur le bou-
chon du radiateur.
D
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-
rant renversé avant de faire démarrer le moteur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
D
D
LA CHALEUR DU MOTEUR peut pro-
voquer un incendie.
Jeter les chiffons dans un récipient ignifuge.
D
Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces inflammables.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Tenir
à
distance les produits inflammables de
l’échappement.
D
Ne pas approcher les mains des ventilateurs, cour-
roies et autres pièces en mouvement.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
D
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
D
Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé −
voir codes en vigueur.
D
Arrêter le moteur avant d’installer ou brancher l’appareil.
D
Demander seulement à un personnel qualifié d’enlever les dispositifs de
sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’en-
tretien et de dépannage.
D
2-4. Dangers liés à l’air comprimé
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un in-
cendie ou une explosion.
RESPIRER L’AIR COMPRIMÉ peut pro-
voquer des blessures graves ou causer
la mort.
D
Ne pas utiliser l’air comprimé pour respirer.
D
Ne pas couper ou gouger à proximité de produits
inflammables.
D
Utiliser l’air comprimé seulement pour le coupa-
ge, gougeage et les outils pneumatiques.
D
Surveillez et garder un extincteur à proximité.
L’AIR COMPRIMÉ peut provoquer
des blessures.
DES PIECES CHAUDES peuvent provo-
quer des brûlures et blessures.
D
Porter des lunettes de sécurité approuvées.
D
Ne pas toucher le compresseur ou d’autres élé-
ments du circuit air comprimé chauds.
D
Ne pas diriger le jet d’air vers d’autres ou soi−
même.
D
Laisser l’ensemble se refroidir avant de toucher
ou d’effectuer la maintenance.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provo-
quer des blessures.
LIRE LES INSTRUCTIONS.
D
Relâcher la pression d’air de l’outillage ou du sys-
tème avant d’effectuer la maintenance, avant de
changer ou de rajouter des éléments ou avant
d’ouvrir la purge ou le bouchon de remplissage
d’huile.
D
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
Arrêter le moteur et relâcher la pression avant
d’effectuer la maintenance.
D
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la
maintenance
D
Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
LA CHUTE DE L’APPAREIL peut
blesser.
D
D
Utiliser l’anneau de levage uniquement pour soulever
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.
OM-494 Page 7
Download from Www.Somanuals.com. All Manuals Search And Download.
LE SURCHAUFFEMENT peut endom-
mager le moteur électrique.
LIRE LES INSTRUCTIONS.
D
D
Utiliser seulement les pièces de rechange d’origine.
Effectuer la maintenance du moteur et du compres-
seur (si applicable) suivant ce manuel et le manuel du
moteur/compresseur (si applicable).
D
Arrêter ou déconnecter l’équipement avant de dé-
marrer ou d’arrêter le moteur.
D
Ne pas laisser tourner le moteur trop lentement sous
risque d’endommager le moteur électrique à cause
d’une tension et d’une fréquence trop faibles.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
D
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.
D
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements
de radio−navigation et de communication, les
services de sécurité et les ordinateurs.
D
Porter un écran facial pour protéger le visage et les
yeux.
D
D
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.
D
D
Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de pro-
tecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque
l’on porte l’équipement homologué de protection du visage, des mains et
du corps.
Les étincelles risquent de causer un incendie − éloigner toute substance
inflammable.
D
D
D
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
D
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
Ne pas obstruer les passages d’air du poste.
D
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement com-
mandé par ordinateur tel que les robots.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les
circuits imprimés.
D
D
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.
D
Établir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
D
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
D
D
D
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
D
Utiliser les supports de la remorque ou des blocs
pour soutenir le poids.
D
Installer convenablement le poste sur la remorque
comme indiqué dans le manuel s’y rapportant.
2-6. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (télé-
phone : (305) 443−9353, site Web : www.aws.org).
Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à To-
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site
Web : www.ansi.org).
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping, norme American Welding Society AWS F4.1, de
l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (télé-
phone : (305) 443−9353, site Web : www.aws.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,
norme NFPA 51B, de la National Fire Protection Association, P.O. Box
9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
National Electrical Code, norme NFPA 70, de la National Fire Protection As-
sociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de
la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web :
www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
Web : www.osha.gov).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Cana-
dian Standards Association, Standards Sales, 178 boulevard Rexdale,
2-7. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques
basse fréquence sur l’organisme
Afin de réduire les champs électromagnétiques en milieu de travail, respec-
ter les consignes suivantes :
En parcourant les câbles de soudage, le courant crée des champs électro-
magnétiques. Les effets potentiels de tels champs restent préoccupants.
Cependant, après avoir examiné plus de 500 études qui ont été faites pen-
dant une période de recherche de 17 ans, un comité de spécialistes du
National Research Council a conclu : « L’accumulation de preuves n’a pas
démontré que l’exposition aux champs magnétiques et aux champs électri-
ques à haute fréquence constitue un risque pour la santé humaine ».
Toutefois, les études et l’examen des preuves se poursuivent. En attendant
les conclusions finales de la recherche, il serait souhaitable de réduire l’ex-
position aux champs électromagnétiques pendant le soudage ou le
coupage.
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-
mandé de respecter les consignes ci-dessus.
OM-494 Page 8
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 3 − DEFINITIONS
3-1. Symbols And Definitions
Stop Engine
Start Engine
Ether Starting Aid
Circuit Breaker
Engine
Do Not Switch
While Welding
Or Under Load
Battery (Engine)
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Protective Earth
(Ground)
Fuel
Certified/Trained
Mechanic
Positive
Negative
Welding Arc
Remote
Amperes
Volts
Panel/Local
A V
Alternating
Current
On
Temperature
Output (Contactor)
Stick (SMAW)
Welding
TIG (GTAW)
Welding
MIG (GMAW)
Welding
Three Phase
Single Phase
3
1
Time
Hours
Seconds
h
s
Read Operator’s
Manual
OM-494 Page 9
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 4 − SPECIFICATIONS
4-1. Description
This unit has two CC/CV modules with separate weld controls for applications where two welding arcs are needed. A
Welder Selector switch controls whether one or both sets of weld output terminals are active (see Section 6-2). When
the unit is operated in the dual operator mode, each welder has CC and CV weld output available for Stick, TIG, and
MIG welding. When in the single operator mode, CC weld output is available to the welder on the Welder B (right) side
only (CV not active in single operator mode).
4-2. Weld, Power, And Engine Specifications
Max.
Weld
Stations
Available
Weld
Output
Range
Rated
Welding
Output
Weld
Mode
Weld
Output
Open-
Circuit
Voltage
Generator Power
Rating
Fuel
Capacity
Engine
550 A at 30
Volts DC, 40%
Duty Cycle
1
Single-Phase,
4 kVA/kW, 34/17 A,
120/240 V AC,
50/60 Hz
Single
Dual
CC/DC
30 − 600 A
85
Deutz F3L-912
Air-Cooled,
Three-Cylinder,
41.5 HP Diesel
Engine
(Right Side)
22.3 gal
(84.4 L)
CC/DC
CV/DC
15 − 300 A
85
49
275 A at 31
Volts DC, 40%
Duty Cycle
2
(4 kVA/kW Shared By
All Receptacles)
(Both Sides)
10 − 32 V
4-3. Dimensions, Weights, And Operating Angles
Dimensions
Height
47-5/8 in (1210 mm)
31-1/4 in (794 mm)
60-1/2 in (1537 mm)
59-1/8 in (1502 mm)
47-1/4 in (1200 mm)
43-1/4 in (1099 mm)
32-3/4 in (832 mm)
24-15/16in (633 mm)
10-1/2 in (267 mm)
6-1/2 in (165 mm)
2-7/8 in (73 mm)
L
Width
Y
Y
Do not exceed tilt angles or engine could
be damaged or unit could tip.
Engine End
Depth
A
B
C
D
E
F
Do not move or operate unit where it could
tip.
A
C
B
D
G
H
J
E
17.5°
F
17.5°
29-7/8 in (759 mm)
11/16 in (24 mm)
20°
20°
G
K
H
K
J
21/32 in (17 mm) Dia.
16 Holes
L
angles_1 8/99
158 699
Weight
2005 lb (909 kg)
OM-494 Page 10
Download from Www.Somanuals.com. All Manuals Search And Download.
4-4. Fuel Consumption
The curve shows typical fuel use un-
der the combined weld loads of both
sides (Welder A and Welder B).
7.57
6.62
5.67
4.73
3.78
2.84
1.98
0.95
1.70 2.00
1.46 1.75
1.25 1.50
1.04 1.25
0.83 1.00
0.62 0.75
0.40 0.50
0.21 0.25
0
CC
CV
0
50 100 150 200 250 300 350 400 450 500 550 600
DC WELD AMPERES AT 40% DUTY CYCLE
195 711
4-5. AC Generator Power
The ac power curve shows the gen-
erator power in amperes available
at the 120 and 240 volt receptacles.
150 300
125 250
100 200
75 150
50 100
25 50
0
0
0
0
5
10
15
20
25
50
30
60
AC AMPERES IN 240V MODE
10
20 30 40
AC AMPERES IN 120V MODE
193 018
OM-494 Page 11
Download from Www.Somanuals.com. All Manuals Search And Download.
4-6. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
Y
Exceeding duty cycle can
damage unit and void
warranty.
Dual Operator Mode − 40% Duty Cycle At 275 Amperes From Each Side
Single Operator Mode − 40% Duty Cycle At 550 Amperes From Welder B side (Right)
If a weld module overheats, the
High Temperature light goes on and
the thermostat opens to stop weld
output to that module. Wait fifteen
minutes for module to cool. Reduce
amperage, voltage, or duty cycle
before welding.
4 Minutes Welding
6 Minutes Resting
This unit has separate duty cycle
ratings for each operating mode. If
the unit is operated in the dual oper-
ator mode, the unit is rated at 40%
duty cycle. This means each side of
the unit can be operated at 275 am-
peres at 40% duty cycle.
When the unit is operated in the
single operator mode, the WelderB
side (right) is rated at 40% duty
cycle (550 A at 40% duty cycle).
Overheating
A or V
0
15
OR
Reduce Duty Cycle
Minutes
Ref. rduty1 5/95 − 194 313-A
OM-494 Page 12
Download from Www.Somanuals.com. All Manuals Search And Download.
4-7. Volt-Ampere Curves
The volt-ampere curve shows the
minimum, medium, and maximum
voltage and amperage output capa-
bilities of the welding generator.
Curves of all other settings fall be-
tween the curves shown.
A. CC/DC − Single Mode
100
80
60
MIN
MED
MAX
40
20
0
0
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
B. CC/DC − Dual Mode
100
80
MIN
MED
MAX
60
40
20
0
0
50 100 150 200 250 300 350 400 450 500
DC AMPERES
C. CV/DC Mode
100
80
60
40
MAX
MED
MIN
20
0
0
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
194 397 / 194 398 / 194 399
OM-494 Page 13
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 5 − INSTALLATION
When facing the front panel, the Welder B controls and weld terminals are on the
right and the Welder A controls and weld terminals are on the left.
NOTE
5-1. Installing Welding Generator
Movement
Airflow Clearance
Location
18 in
(460 mm)
Y
Do Not Lift Unit From End
18 in
(460 mm)
18 in
(460 mm)
OR
OR
18 in
(460 mm)
18 in
(460 mm)
Grounding
Y
Y
Always securely fasten welding
generator onto transport vehicle
or trailer and comply with all DOT
and other applicable codes.
1
2
GND/PE
Always ground generator frame
to vehicle frame to prevent elec-
tric shock and static electricity
hazards.
Y
If unit does not have GFCI recep-
tacles, use GFCI-protected ex-
tension cord.
1
Equipment Grounding Terminal
(On Front Panel)
Electrically bond generator frame to
vehicle frame by metal-to-metal
contact.
2
3
Grounding Cable (Not Supplied)
Metal Vehicle Frame
3
Connect cable from equipment ground
terminalto metal vehicle frame. Use #10
AWG or larger insulated copper wire.
Y
Bed liners, shipping skids, and some running
gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding termi-
nal to bare metal on the vehicle frame as shown.
Y
Be sure equipment connected to
the 240 V receptacles is GFCI-
protected.
install1 11/02* − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-494 Page 14
Download from Www.Somanuals.com. All Manuals Search And Download.
5-2. Activating The Dry Charge Battery
Remove battery from unit.
1
Eye Protection − Safety
Glasses Or Face Shield
2
3
4
Rubber Gloves
Vent Caps
5
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
5
Well
4
1
Fill each cell with electrolyte to
bottom of well (maximum).
3
Y
Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
6
Battery Charger
Y
Read and follow all instruc-
tions supplied with battery
charger.
2
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am-
peres. Disconnect charging cables
and install battery.
. When electrolyte is low, add
only distilled water to cells to
maintainproper level.
6
5 A For 30 Minutes
OR
+
−
Tools Needed:
30 A For 12 Minutes
drybatt1 2/96 − S-0886
OM-494 Page 15
Download from Www.Somanuals.com. All Manuals Search And Download.
5-3. Connecting The Battery
Y
Connect (−) Cable Last.
+
−
190 377
5-4. Installing Exhaust Pipe
Y
Y
Stop engine and let cool.
Do not blow exhaust toward
air cleaner or air intake.
Top View
Tools Needed:
1/2 in
exh_pipe2 4/96 − 154 089-A / 154 611 / 190 377
OM-494 Page 16
Download from Www.Somanuals.com. All Manuals Search And Download.
5-5. Engine Prestart Checks
Check all fluids daily. Engine must
be cold and on a level surface.
Follow run-in procedure in engine
manual.If unburned fuel and oil col-
lect in exhaust pipe during run-in,
1/2 in
(13 mm)
Fuel
Full
Y
Do not use gasoline. Gaso-
line will damage engine.
Add diesel fuel before starting
engine the first time (see mainte-
nance label for specifications). Fill
fuel tank up to 1/2 in. (13 mm) from
top to allow room for expansion.
Open fuel shut-off valve.
Diesel
Do not run out of fuel or air enters
fuel system and causes starting
problems. See engine manual to
bleed air from fuel system.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see main-
tenance label).
.
E
n
g
i
n
e
s
t
o
p
s
i
f
o
i
l
p
r
e
s
s
u
r
e
i
s
too low.
.
T
o
i
m
p
r
o
v
e
c
o
l
d
w
e
a
t
h
e
r
Valve Open
starting:
Keep battery in good condition.
Store battery in warm area.
Use fuel formulated for cold
weather (diesel fuel can gel in
cold weather). Contact local
fuel supplier for fuel in-
formation.
Full
Use correct grade oil for cold
weather.
Ref. 158 633-C / S-176 697
Notes
Start Your Professional
Welding Career Now!
Over 80,000 trained
since 1930!
400 Trade Square East, Troy, Ohio 45373
OM-494 Page 17
Download from Www.Somanuals.com. All Manuals Search And Download.
5-6. Safety Information For Connecting To Weld Output Terminals
Y
UNEXPECTED WELD OUTPUT can cause injury or fire.
D
D
Both weld outputs can be live (ON) when Welder Selector switch is in Welder A/Welder B position and engine is running.
Disconnect or insulate any unused cables.
D
Know where cables are located BEFORE starting engine.
Y
ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical connections.
D
D
Stop engine before making any weld output connections.
Do not connect welding output of different polarities to the same structure.
D
See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual).
When welding on the same workpiece, all connections to the workpiece must be of the same polarity.
Do not handle or come in contact with two live electrodes at the same time.
D
D
Y
ELECTRIC SHOCK can kill; TWO TIMES NORMAL OPEN-CIRCUIT VOLTS can exist between electrode holders of opposite polarity.
D
D
D
Do not touch electrode holders of opposite polarity at the same time.
Separate electrode holders of opposite polarity to prevent contact.
Consult ANSI Z49.1 for common grounding safe practices.
5-7. Weld Output Terminals
Welder B (Right) Side
Welder A (Left) Side
3
2
1
1
2
3
.
D
i
n
s
e
r
e
c
e
p
t
a
c
l
e
s
o
n
l
y
o
n
u
n
i
t
s
with Polarity switch option.
Tools Needed:
3/4 in
4
Ref. 190 377 / 802 292-A / 802 554
Y
Stop engine.
4
Dinse Weld Receptacles (Only On
Units With Polarity Switch Option)
connections (CC only).
If unit has the Polarity switch option, the
Negative (−) weld output terminals are la-
beled Work receptacles and the CC weld
output terminals are labeled Electrode re-
ceptacles.
1
Negative (−) Weld Output Terminal
output connections for CC and CV welding.
2
3
CV Weld Output Terminal
CC Weld Output Terminal
See Section 5-14 for single operator output
OM-494 Page 18
Download from Www.Somanuals.com. All Manuals Search And Download.
5-8. Making Dual Operator CC Weld Connections w/ Separate Work Cables
Tools Needed:
3/4 in
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B (Right) Side
Welder A (Left) Side
Note position
of Process
Selector
switches.
2
2
1
3
Ref. 190 377 / 802 292-A
Y
Y
Stop engine.
Do not exceed machine duty cycle.
2
3
Electrode Holder Cables
Work Cables
CC terminals and electrode holder cables
to Negative (−) terminals.
If unit has the Polarity switch option, con-
nect work cables to Work receptacles and
electrodeholder cables to Electrode recep-
tacles.
For Stick/TIG welding Direct Current Elec-
trode Positive (DCEP), connect work
cables to Negative (−) terminals and elec-
trode holder cables to CC terminals.
For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cables to
.
U
s
e
D
u
a
l
O
p
e
r
a
t
o
r
m
o
d
e
f
o
r
C
C
a
n
d
See Section 5-15 for proper cable size.
1
Strain Reliefs
.
B
e
s
u
r
e
P
r
o
c
e
s
s
S
e
l
e
c
t
o
r
s
w
i
t
c
h
e
s
a
r
e
Route cables through strain reliefs.
OM-494 Page 19
Download from Www.Somanuals.com. All Manuals Search And Download.
5-9. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable
Tools Needed:
3/4 in
Y
INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.
When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−) weld termi-
nals, and connect a single weld cable of adequate size from the Welder B (right) Negative (−) terminal to the workpiece.
When using these connections as a common work terminal, all connections must be of the same polarity.
for proper cable size).
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B (Right) Side
Welder A (Left) Side
Note position
of Process
Selector
switches.
1
4
2
2
3
Ref. 190 377 / 802 292-A
Y
Y
Stop engine.
Do not exceed machine duty cycle.
4
Common Work Cable
work jumper cable to Welder A (left) CC ter-
minal.
For Stick/TIG welding Direct Current Elec-
trode Positive (DCEP), connect common
work cable and work jumper cable to Weld-
er B (right) Negative (−) terminal. Connect
other end of work jumper cable to Welder A
(left) Negative (−) terminal.
Connect electrode holder cables to Nega-
tive (−) terminals.
. For common work connection, work
cable must be able to carry combined
weld output of both CC weld output ter-
cable size).
If unit has the Polarity switch option, con-
nect common work cable and work jumper
cable to Welder B (right) Work receptacle.
Connect other end of work jumper cable to
Welder A (left) Work receptacle.
Connect electrode holder cables to Elec-
trode receptacles.
.
U
s
e
D
u
a
l
O
p
e
r
a
t
o
r
m
o
d
e
f
o
r
C
C
a
n
d
Connect electrode holder cables to CC ter-
minals.
1
Strain Relief
For Stick/TIG Direct Current Electrode
Negative (DCEN), connect common work
cable and work jumper cable to Welder B
(right) CC terminal. Connect other end of
Route cables through strain reliefs.
2
3
. Be sure Process Selector switches
and optional Polarity switches are set
Electrode Holder Cables
Work Jumper Cable
OM-494 Page 20
Download from Www.Somanuals.com. All Manuals Search And Download.
5-10. Making Dual Operator CV Weld Connections w/ Separate Work Cables
Tools Needed:
3/4 in
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B (Right) Side
Welder A (Left) Side
Note position
of Process
Selector
switches.
Note position
of optional Po-
larity switch.
Note position
of optional
Polarity
2
2
switch.
1
3
Ref. 190 377 / 802 292-A
Y
Y
Stop engine.
3
Work Cables
If unit has the Polarity switch option, con-
nect work cables to Work receptacles and
wire feeder cables to CV receptacles.
Do not exceed machine duty cycle.
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect work
cables to Negative (−) terminals and wire
feeder cables to CV terminals.
.
U
s
e
D
u
a
l
O
p
e
r
a
t
o
r
m
o
d
e
f
o
r
C
C
a
n
d
. Place optional Polarity switches in Re-
verse position when using CV weld re-
ceptacles. There is no CV weld output
when switch is in Straight position.
See Section 5-15 for proper cable size.
1
Strain Reliefs
Route cables through strain reliefs.
Wire Feeder Cables
For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect work
cables to CV terminals and wire feeder
cables to Negative (−) terminals.
. Be sure Process Selector and Polarity
switches are set correctly. See Section
6-3.
2
OM-494 Page 21
Download from Www.Somanuals.com. All Manuals Search And Download.
5-11. Making Dual Operator CV Weld Connections w/ Common Work Cable
Tools Needed:
3/4 in
Y
INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.
When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−) weld termi-
nals, and connect a single weld cable of adequate size from the Welder B (right) Negative (−) terminal to the workpiece.
When using these connections as a common work terminal, all connections must be of the same polarity.
For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see Section 5-15
for proper cable size).
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B (Right) Side
Welder A (Left) Side
Note position
of Process
Selector
switches.
1
Note position
of optional
Polarity
Note position of optional
Polarity switch.
4
switch.
2
2
3
Ref. 190 377 / 802 292-A
Y
Y
Stop engine.
Do not exceed machine duty cycle.
4
Common Work Cable
Connect wire feeder cables to Negative (−)
terminals.
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect com-
mon work cable and work jumper cable to
Welder B (right) Negative (−) terminal. Con-
nect other end of work jumper cable to
Welder A (left) Negative (−) terminal.
If unit has the Polarity switch option, con-
nect common work cable and work jumper
cable to Welder B (right) Work receptacle.
Connect other end of work jumper cable to
Welder A (left) Work receptacle.
Connect wire feeder cables to CV recep-
tacles.
. For common work connection, work
cable must be able to carry combined
weld output of both CC weld output ter-
cable size).
Connect wire feeder cables to CV termi-
nals.
.
U
s
e
D
u
a
l
O
p
e
r
a
t
o
r
m
o
d
e
f
o
r
C
C
a
n
d
. Place optional Polarity switches in Re-
verse position when using CV weld re-
ceptacles. There is no CV weld output
when switch is in Straight position.
For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect common
work cable and work jumper cable to Weld-
er B (right) CV terminal. Connect other end
of work jumper cable to Welder A (left) CV
terminal.
1
Strain Relief
Route cables through strain reliefs.
. Be sure Process Selector and Polarity
switches are set correctly. See Section
6-3.
2
3
Wire Feeder Cables
Work Jumper Cable
OM-494 Page 22
Download from Www.Somanuals.com. All Manuals Search And Download.
5-12. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables
Tools Needed:
3/4 in
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B (Right) Side
Welder A (Left) Side
Note position
of Process
Selector
switches.
1
Note position
of optional
Polarity
3
2
switch.
4
Ref. 190 377 / 802 292-A
Y
Y
Stop engine.
to Negative (−) terminal and electrode hold-
For Stick/TIG welding on units with Polarity
switch option, connect work cable to Work
receptacle and electrode cable to Electrode
receptacle.
er cable to CC terminal.
Do not exceed machine duty cycle.
For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cable to
CC terminal and electrode holder cable to
Negative (−) terminal.
.
U
s
e
D
u
a
l
O
p
e
r
a
t
o
r
m
o
d
e
f
o
r
C
C
a
n
d
For MIG/FCAW welding on units with Polar-
ity switch option, connect work cable to
Work receptacle and wire feeder cable to
CV receptacle.
See Section 5-15 for proper cable size.
.
B
e
s
u
r
e
P
r
o
c
e
s
s
S
e
l
e
c
t
o
r
s
w
i
t
c
h
e
s
a
r
e
1
Strain Reliefs
Route cables through strain reliefs.
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect work
cable to Negative (−) terminal and wire
feeder cable to CV terminal.
. Place optional Polarity switches in Re-
verse position when using CV weld re-
ceptacles. There is no CV weld output
when switch is in Straight position.
2
3
4
Electrode Holder Cable
Wire Feeder Cable
Work Cables
For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect work
cable to CV terminal and wire feeder cable
to Negative (−) terminal.
.
B
e
s
u
r
e
P
r
o
c
e
s
s
S
e
l
e
c
t
o
r
a
n
d
P
o
l
a
r
i
t
y
For Stick/TIG welding Direct Current Elec-
trode Positive (DCEP), connect work cable
switches are set correctly. See Section
6-3.
OM-494 Page 23
Download from Www.Somanuals.com. All Manuals Search And Download.
5-13. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable
Tools Needed:
3/4 in
Y
INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.
When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−) weld termi-
nals, and connect a single weld cable of adequate size from the Welder B (right) Negative (−) terminal to the workpiece.
When using these connections as a common work terminal, all connections must be of the same polarity.
For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see Section 5-15
for proper cable size).
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B (Right) Side
Welder A (Left) Side
Note position
of Process
Selector
switches.
1
5
2
Note position of
optional Polarity
switch.
3
4
Ref. 190 377 / 802 292-A
Y
Y
Stop engine.
Do not exceed machine duty cycle.
For Direct Current Electrode Positive
(DCEP), connect common work cable and
work jumper cable to Welder B (right) Nega-
tive (−) terminal. Connect other end of work
jumper cable to Welder A (left) Negative (−)
terminal.
Connect electrode holder cable to either
Negative (−) terminal, and wire feeder cable
to remaining Negative (−) terminal.
If unit has the Polarity switch option, connect
common work cable and work jumper cable
to Welder B (right) Work receptacle. Con-
nect other end of work jumper cable to Weld-
er A (left) Work receptacle.
Connect electrode holder cable to either
Electrode receptacle.
Connect wire feeder cable to CV receptacle
on other side.
. For common work connection, work
cable must be able to carry combined
weld output of both CC weld output ter-
cable size).
Connect electrode holder cable to either CC
terminal.
.
U
s
e
D
u
a
l
O
p
e
r
a
t
o
r
m
o
d
e
f
o
r
C
C
a
n
d
C
V
Connect wire feeder cable to CV terminal on
other side.
1
Strain Reliefs
.
B
e
s
u
r
e
P
r
o
c
e
s
s
S
e
l
e
c
t
o
r
s
w
i
t
c
h
e
s
a
r
e
. Place optional Polarity switch in Re-
verse position when using CV weld re-
ceptacle. There is no CV weld output
when switch is in Straight position.
Route cables through strain reliefs.
2
3
4
5
Electrode Holder Cable
Wire Feeder Cable
For Direct Current Electrode Negative
(DCEN), connect common work cable and
work jumper cable to Welder B (right) CC
terminal.Connect other end of work jumper
cable to Welder A (left) CV terminal.
. Be sure Process Selector and Polarity
switches are set correctly. See Section
6-3.
Work Jumper Cable
Common Work Cable
OM-494 Page 24
Download from Www.Somanuals.com. All Manuals Search And Download.
5-14. Making Single Operator CC Weld Connections
Direct Current Electrode Positive
(DCEP) connections are shown.
Welder B(Right) Side
Welder A (left) Terminals Inactive
In Single Operator Mode
Note position
of Process
Selector
switch.
1
3
2
Tools Needed:
3/4 in
190 377 / 802 292-A
Y
Y
Stop engine.
Single Operator mode. (see Section
5-8).
to Negative (−) terminal and electrode hold-
er cable to CC terminal.
Do not exceed machine duty cycle.
For Stick/TIG Direct Current Electrode Neg-
ative (DCEN), connect work cable to CC
terminaland electrode holder cable to Neg-
ative (−) receptacle.
If unit has the Polarity switch option, con-
nect work cable to Work terminal and elec-
trode holder cable to Electrode receptacle.
Strain Relief
Route cables through strain reliefs.
Electrode Holder Cable
Work Cable
For Stick/TIG welding Direct Current Elec-
trode Positive (DCEP), connect work cable
. Welder A (left) weld output terminals
are disabled in Single Operator mode.
Connect only to Welder B (right) termi-
nals for Single Operator mode opera-
tion.
1
2
3
. Use Single Operator mode for CC weld-
ing only. Welder A and Welder B CV
weld output terminals are disabled in
.
B
e
s
u
r
e
P
r
o
c
e
s
s
S
e
l
e
c
t
o
r
s
w
i
t
c
h
i
s
s
e
t
OM-494 Page 25
Download from Www.Somanuals.com. All Manuals Search And Download.
5-15. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft
(45 m)
200 ft
250 ft
300 ft
350 ft
400 ft
100 ft (30 m) or Less
(60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Y
Y
Turn off power before
connectingto weld out-
put terminals.
10 − 60% 60 − 100%
Welding
Amperes
Duty
Duty
10 − 100% Duty Cycle
Cycle
Cycle
Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
100
150
200
4 (20)
3 (30)
3 (30)
4 (20)
3 (30)
2 (35)
4 (20)
2 (35)
1 (50)
3 (30)
1 (50)
2 (35)
1/0 (60)
2/0 (70)
1 (50)
1/0 (60)
3/0 (95)
1/0 (60)
3/0 (95)
2/0 (70)
1/0 (60)
3/0 (95) 4/0 (120) 4/0 (120)
2 ea. 2/0 2 ea. 2/0
250
300
350
400
2 (35)
1 (50)
1 (50)
1/0 (60)
2/0 (70)
2/0 (70)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
4/0 (120)
2/0 (70)
3/0 (95) 4/0 (120)
(2x70)
(2x70)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0
(2x70) (2x95) (2x95)
3/0 (95) 4/0 (120)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0
(2x70) (2x95) (2x95) (2x120)
1/0 (60)
1/0 (60)
4/0 (120)
4/0 (120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0
(2x70) (2x95) (2x120) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
(2x70) (2x95) (2x120) (3x95) (3x95)
500
600
700
800
2/0 (70)
3/0 (95)
3/0 (95)
2 ea. 2/0
(2x70)
2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0
(2x95) (2x120) (3x95) (3x120) (3x120)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0
(2x120) (3x95) (3x120) (3x120) (4x120)
4/0 (120)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0 4 ea. 4/0
(2x120)
(3x120)
(3x120)
(4x120)
(4x120)
* This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
2
( ) = mm for metric use
S-0007-F
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
OM-494 Page 26
Download from Www.Somanuals.com. All Manuals Search And Download.
5-16. Installing Ether Cylinder (Optional Ether Starting Aid)
Y
Y
Stop engine.
Improper handling or expo-
sure to ether can harm your
health. Follow manufactur-
er’s safety instructions on
cylinder.
1
Y
Do not use Ether Starting Aid
while engine is running.
Open right side door.
1
2
Ether Cylinder
Nozzle
Remove cover and clean cylinder
nozzle.
2
3
4
5
6
Clamp
Fitting
Cap
3
Valve
Remove cap and clean fitting.
Install cylinder on fitting. Tighten
clamp.
4
5
. After installing cylinder, wait at
least 10 minutes before using
to let ether particles settle and
prevent atomizer plugging.
6
Put cap on fitting when cylinder is
removed.
ether1 7/96 − 153 382-A / 190 377 / 802 291-A
5-17. Remote 14 Receptacle Information
Place Welder Selector switch in Welder A/Welder B position (dual operator mode) for
both remote receptacles to work. Welder A (left) remote receptacle output contactor
and control is disabled when switch is in Welder B position.
NOTE
Socket*
Socket Information
A
B
C
D
E
24 volts ac. Protected by circuit breakers CB5 and CB6.
Contact closure to A completes 24 volts ac contactor control circuit.
Output to remote control; +10 volts dc in CV, 0 to +10 volts dc in CC.
Remote control circuit common.
24 VOLTS AC
REMOTE
OUTPUT
CONTROL
0 to +10 volts dc input command signal from remote control.
F
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
Voltage feedback; +1 volts dc per 10 arc volts.
A/V
AMPERAGE
VOLTAGE
H
115 VOLTS AC
I
115 volts, 15 amperes, 60 Hz ac. Protected by circuit breakers CB5 and CB6.
Contact closure to I completes 115 volts ac contactor control circuit.
J
K
Chassis common.
GND
G
Circuit common for 24 and 115 volts ac circuits.
*The remaining sockets are not used.
OM-494 Page 27
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 6 − OPERATING THE WELDING GENERATOR
When facing the front panel, the Welder B controls and weld terminals are on the
right and the Welder A side controls and weld terminals are on the left.
NOTE
6-1. Engine Controls
3
4
1
5
2
190 377
To Start: Press button and use Ether switch To Stop: Pull control out and hold. Release
.
S
e
e
S
e
c
t
i
o
n
f
o
r
w
e
l
d
c
o
n
t
r
o
l
control when engine stops.
Battery Charging Warning Light
Light goes on when battery is not charging.
(if necessary). Release button when engine
starts.
descriptions.
4
1
2
3
Engine Start Button
Manual Stop Control
Ether Starting Aid Switch (Optional)
.
I
f
t
h
e
e
n
g
i
n
e
d
o
e
s
n
o
t
s
t
a
r
t
,
l
e
t
e
n
g
i
n
e
Y
If light goes on, stop engine and check
engine belt.
come to a complete stop before attempt-
Push switch up and release while cranking
engine to release ether.
ing restart.
5
Engine Hour Meter
OM-494 Page 29
Download from Www.Somanuals.com. All Manuals Search And Download.
1
Welder Selector Switch
3
Arc Force (Dig) Control
6
Weld Meters
Use switch to select Dual Operator or Single
Operator welding mode.
Use control to automatically increase amper-
age as arc length is decreased to assist in arc
starts and reduce the chance of the electrode
sticking in the puddle. Turn clockwise to in-
crease short-circuit amperage. Set at mini-
mum for TIG welding.
With Process Selector switch in the Stick/Tig
position, meters read 0 (zero) with contactor
off. Meters display actual output voltage and
amperagewith contactor on.
Place switch in Welder A/Welder B (dual oper-
ator) position for CC and CV output from Weld-
er A (left) and Welder B (right) weld output ter-
minals. Control the weld output from the termi-
nals on each side using the weld controls on
that same side.
With Process Selector switch in the MIG posi-
tion, voltmeter displays preset voltage with
contactor off. Voltmeter and ammeter display
actual output voltage and amperage with con-
tactor on.
4
Hot Start Switch
Place switch in Welder B (single operator)
position for CC weld output from Welder B
(right) weld output terminals only. CV weld out-
put terminals on both sides do not work when
unit is in Single Operator mode.
Use switch to disable hot start circuit. Turn
switch On for Stick (SMAW) and Submerged
Arc (SAW) Welding, and Air Carbon Arc Cut-
ting and Gouging (CAC-A). Turn switch Off for
TIG (GTAW) welding.
7
High Temperature Shutdown Light
Light goes on and weld output stops if weld
rectifier gets too warm. Let unit cool before
welding.
. Welder A (left) weld output terminals are
disabled in Single Operator mode. Con-
nect only to Welder B (right) terminals for
Single Operator operation.
When switch is in On position, higher short-cir-
cuit amperage helps arc starting. After arc
starts, the front panel or remote Amperage/
Voltage control setting determines weld am-
perage.
8
Remote Amperage/Voltage Control
Switch
. When in single Operator mode, only CC
weld output is available. Welder A (left)
and Welder B (right) side CV weld output
terminals are disabled in Single Operator
For front panel control, place switch in Panel
position. For remote control, place switch in
Remote position, and connect remote device
.
T
h
e
h
o
t
s
t
a
r
t
c
i
r
c
u
i
t
d
o
e
s
n
o
t
f
u
n
c
t
i
o
n
when constant voltage (CV) welding.
5
Amperage/Voltage Control
9
Output (Contactor) Switch
2
Process Selector Switch
When Process Selector switch is in the Stick/
TIG position, turn control clockwise to in-
crease amperage. Read amperage from outer
scale of control. The Amperage/Voltage con-
trol adjusts amperage only when constant cur-
rent (CC) welding and does not adjust open-
circuit voltage.
Use switch to select output for weld process.
If switch is in Stick/Tig position, place Welder
Selector switch in Welder A/Welder B or Weld-
er B Position. If switch is in MIG position, place
Welder Selector switch in Welder A/Welder B
position only.
For front panel control of output, place switch
in On (Hot) position. For remote control of out-
put, place switch in Remote position, and con-
Y
Weld output terminals are energized
when Output (Contactor) switch is On
and engine is running.
. CV weld output for MIG is only available
when Welder Selector switch is in Welder
A/Welder B position. All weld output
stops if either Process Selector switch
is placed in MIG position when Welder
Selector switch is in Welder B position.
When Process Selector switch is in the MIG
position, turn control clockwise to increase
voltage. Voltmeter value changes as control
knob is turned. Control can be adjusted while
welding.
10 Polarity Switch (Optional)
Do not switch under load.
Y
Use switch to change polarity of weld output
. Place optional Polarity switch in Reverse
position when using CV weld output.
There is no CV weld output when Polarity
switch is in Straight position.
. When Welder Selector switch is in Welder
B position (single operator mode), weld
amperageis two times the value selected
by the Amperage/Voltage control. For ex-
ample, if Amperage/Voltage control is set
to 250 A, weld output is actually 500A.
. Place optional Polarity switch in Reverse
position when using CV weld receptacle.
There is no CV weld output when switch is
in Straight position.
Y
Do not switch under load or with out-
put on.
OM-494 Page 31
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 7 − OPERATING AUXILIARY EQUIPMENT
7-1. 120 Volt And 240 Volt Duplex Receptacles
4
6
3
2
5
1
190 376
Y
Be sure equipment connected to the
240 V receptacles is GFCI-pro-
tected.
faulty equipment and the GFCI Reset but-
RC2. If CB4 opens, GFCI 2 does not work.
Press button to reset breaker.
ton pops out. Check for damaged tools,
cords, plugs, etc. connected to the recep-
tacle. Press button to reset receptacle and
resume operation.
. If a circuit breaker continues to open,
contact Factory Authorized Service
Agent.
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
i
s
n
o
t
a
f
f
e
c
t
e
d
b
y
position of Welder Selector switch.
. At least once a month, run engine at
weld/powerspeed and press Test but-
ton to verify GFCI is working properly.
.
4
k
V
A
/
k
W
g
e
n
e
r
a
t
o
r
p
o
w
e
r
o
u
t
p
u
t
i
s
Maximum output from each 120 volt GFCI
receptacleis 2.4 kVA/kW. Maximum output
from each 240 volt duplex receptacle half is
4.0 kVA/kW.
shared by all receptacles.
1
2
240 V 20 A AC Receptacle RC1
120 V 20 A AC GFCI Receptacle
GFCI 1
240 V 20 A AC Receptacle RC2
120 V 20 A AC GFCI Receptacle
GFCI 2
5
6
Circuit Breakers CB1 And CB2
Circuit Breakers CB3 And CB4
Total combined output from all receptacles
is 4 kVA/kW.
CB1 and CB2 protect RC1 and GFCI 1 from
overload. If CB1 or CB2 opens, RC1 does
not work. 120 volts may still be present at
RC1. If CB2 opens, GFCI 1 does not work.
Press button to reset breaker.
3
4
EXAMPLE:If 12 A is drawn from RC1, only
9 A is available at GFCI 1:
Receptacles supply 60 Hz single-phase
power at weld/power speed.
If a ground fault is detected, the GFCI re-
ceptacle(s) circuit opens to disconnect the
(240 V x 12 A) + (120 V x 9 A) = 4.0 kVA/kW
CB3 and CB4 protect RC2 and GFCI 2 from
overload. If CB3 or CB4 opens, RC2 does
not work. 120 volts may still be present at
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
i
s
n
o
t
a
f
f
e
c
t
e
d
b
y
weld output.
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Routine Maintenance
Y
Stop engine before maintaining.
.
S
e
e
E
n
g
i
n
e
M
a
n
u
a
l
a
n
d
M
a
i
n
t
e
n
a
n
c
e
L
a
b
e
l
f
o
r
i
m
-
Recycle
engine
fluids.
portant start-up, service, and storage information.
Service engine more often if used in severe condi-
tions.
*
To be done by Factory Authorized Service Agent.
Every 8 h
Drain Water
FUEL
WATER
Wipe
Up
Spills.
Check Fluid
Levels. See
From Fuel
System. See
OIL
Full
Every 50 h
Clean And
Tighten
Clean Air Filter.
Weld
Terminals.
OM-494 Page 32
Download from Www.Somanuals.com. All Manuals Search And Download.
Every 100 h
Clean And
Tighten
Change Oil
Filter. See
Change Oil. See
Battery
Connections.
Check air cleaner
hoses for cracks
and loose clamps.
Every 200 h
Every 250 h
Replace
Unreadable
Labels.
Check And
Clean Spark
Arrestor. See
Every 500 h
Repair Or
Replace
Cracked
Cables.
Every 1000 h
Blow Out Or
Vacuum Inside.
During Heavy
Service,
Service Welding
Generator Brushes
And Slip Rings.
Service More Often
In Dirty Conditions.*
FUEL
SLUDGE
Drain Sludge
From Fuel
Tank.*
OR
Clean Monthly.
Check
Valve
Clearance.*
Check Belt
Tension. See
1/2 in.
(13 mm)
Change Fuel
Filters. See
OM-494 Page 33
Download from Www.Somanuals.com. All Manuals Search And Download.
8-3. Servicing Air Cleaner
Y
Y
Stop engine.
Do not run engine without air
cleaner or with dirty element. En-
gine damage caused by using a
damaged element is not covered
by the warranty.
1
3
4
2
.
T
h
e
a
i
r
c
l
e
a
n
e
r
p
r
i
m
a
r
y
e
l
e
m
e
n
t
c
a
n
be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.
Optional
5
If you decide to clean the primary ele-
ment, we strongly recommend instal-
ling an optional safety element to pro-
vide additional engine protection.
Never clean a safety element. Re-
place the safety element after servic-
ing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
Keep nozzle
2 in (51 mm)
from element.
1
2
3
4
5
Housing
Safety Element (Optional)
Primary Element
Dust Cap
Dust Ejector
To clean air filter:
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
Blow
Inspect
Y
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 2/01 − ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-494 Page 35
Download from Www.Somanuals.com. All Manuals Search And Download.
8-4. Servicing Fuel And Lubrication Systems
Y
1
Stop engine and let cool.
Oil Filter
2
Oil Drain Plug
3
Oil Drain Hose (Optional)
Oil Fill Cap
4
5
Primary Fuel Filter (Fuel/
Water Separator)
6
7
8
9
Petcock
Secondary Fuel Filter
Fuel Shutoff Valve Lever
Sludge Drain Plug
9
Under Left Side
Of Fuel Tank Behind
Control Panel
To change oil and filter:
See engine manual.
To drain water from fuel system:
Open primary fuel filter petcock and
drain water into metal container.
Close petcock when water-free fuel
flows.
7
To replace primary fuel filter:
Close shutoff valve and turn filter
counterclockwise. Remove filter.
Apply thin coat of fuel to gasket on
new filter. Install new filter and turn
clockwise. Open shutoff valve.
Bleed air from fuel system accord-
ing to engine manual.
4
1
Inspect fuel line, and replace if
cracked or worn.
To replace secondary fuel filter:
See engine manual.
To drain sludge from fuel tank:
. This procedure should only be
done by a Factory Authorized
Service Agent.
Remove Welder A (left) control
panel to access sludge drain plug.
Put metal container under drain and
remove plug. Reinstall plug when
sludge has drained.
2
Reinstall control panel.
Y
After servicing, start engine
and check for fuel leaks.
Valve Open
8
Y
Stop engine, tighten connec-
tions as necessary, and wipe
up spilled fuel.
Close doors.
3
2
5
6
Tools Needed:
3/8, 7/16, 3/4 in
Ref. 158 633-C / Ref. 190 377 / Ref. S-176 697
OM-494 Page 36
Download from Www.Somanuals.com. All Manuals Search And Download.
8-5. Adjusting Engine Speed
Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine
speed with tachometer. See table
for proper no load speed. If neces-
sary, adjust speed as follows:
Engine Speed
(No Load)
RPM
1850
Weld/Power
1
2
High Speed Stop Screw
Lock Nut
Loosen nut. Turn screw out (toward
front of engine) several turns.
3
4
Linkage
Lock Nuts
Loosen nuts. Start engine and
move linkage until engine runs at
weld/power speed. Tighten nuts.
5
Y
Stop engine.
5
Speed Control Lever
Turn screw in until screw touches
lever. Tighten lock nut on screw.
Close side door.
4
3
2
1
Right Side
Tools Needed:
3/8 in
Ref. 045 768-B
8-6. Servicing Optional Ether Starting Aid
Y
Y
Stop engine.
Improper handling or expo-
sure to ether can harm your
health. Follow manufactur-
er’s safety instructions on
cylinder.
If engine does not start in cold
weather, check ether cylinder as
follows:
Remove cylinder from valve.
1
2
3
Ether Cylinder
Valve
1
Scale
Weigh cylinder to see if it is empty.
Be sure atomizer is not plugged and
valve fitting is clean.
Replace cylinder according to
3
33 oz
(935 g)
15 oz
(425 g)
Full
Empty
2
ether2 7/96 − 153 382-A / Ref. 190 377 / S-0692
OM-494 Page 37
Download from Www.Somanuals.com. All Manuals Search And Download.
8-7. Checking And Replacing Alternator Belt
Y
Stop engine.
To check belt tension:
Remove rear panel.
1
2
3
Alternator V-Belt
Crank Pulley
Alternator Pulley
Place straight edge along top of pul-
leys. Pull down belt as far as it will
go, then measure distance from
belt to straight edge.
If measurement is less than 1/2 in
(13 mm), belt is okay. If not okay,
adjust belt tension.
To adjust belt tension:
4
5
Hex Nuts (2)
Alternator Bracket
Loosen nuts. Pivot alternator until
belt is tight. Tighten nuts. Recheck
tightness of belt. Readjust if
necessary.
Replace belt if damaged or
cracked.
To replace belt:
Loosen hex nuts and pivot alterna-
tor clockwise. Remove belt.
Install new belt, pivot alternator until
belt is tight, and tighten nuts. Re-
check tightness of belt after running
engine 15 minutes.
4
Reinstall rear panel.
3
5
1/2 in
(13 mm)
Max
1
2
Tools Needed:
1/2, 11/16 in
158 632 / Ref. 190 377
OM-494 Page 38
Download from Www.Somanuals.com. All Manuals Search And Download.
8-8. Resetting Fan Belt Safety Shutdown
Y
Stop engine.
1
Cooling Fan V-Belt
See engine manual to replace or
tighten belt.
If belt breaks or becomes loose,
safety shutdown stops engine.
Correct problem, then reset safety
shutdown as follows:
2
3
4
5
Rod
Stop
Bracket
Handle
Pull handle towards front of unit un-
til stop snaps in position behind
bracket.
Close door.
1
4
3
5
Right Side
2
Pull Handle To
Reset Shutdown
Tools Needed:
3/8 in
158 715 / Ref. 158 632 / Ref. 190 377
OM-494 Page 39
Download from Www.Somanuals.com. All Manuals Search And Download.
8-9. Inspecting And Cleaning Optional Spark Arrestor Muffler
Y
1
Stop engine and let cool.
Spark Arrestor Muffler
Cleanout Plug
2
Remove plug and remove any dirt
covering cleanout hole.
3
Exhaust Pipe
Start engine and run several min-
utes to blow out cleanout hole. If
nothing blows out of hole, briefly
cover end of exhaust pipe with fire-
proof material.
3
2
1
Y
Stop engine and let cool.
Reinstall cleanout plug.
Tools Needed:
3/8 in
Ref. 800 633-B / Ref. 190 377
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
OM-494 Page 40
Download from Www.Somanuals.com. All Manuals Search And Download.
8-10. Circuit Protection
Tools Needed:
3
4
1
2
7
8
5
6
9
Ref. 802 300 / Ref. 802 292-A
Y
Stop engine.
board PC1. If F4 opens, Welder B (right)
weld output stops.
generator power output may continue if
generator maintains excitation. Weld and
generator power output stops if generator
requires field flashing circuit to restore ex-
citation.
. When a circuit breaker or fuse opens,
it usually indicates a more serious
problem exists. Contact Factory Au-
thorized Service Agent.
5
6
7
8
Circuit Breaker CB5
Circuit Breaker CB6
Circuit Breaker CB7
Circuit Breaker CB8
Press button to reset circuit breaker.
1
2
3
4
Fuse F1
Fuse F2
Fuse F3
Fuse F4
9
Fuses F11, F12, F13, F21, F22, F23
Circuit Breaker CB5 protects the 24 volt
and 115 volt ac output to Welder A (left) re-
mote receptacle RC9. If CB5 opens, Weld-
er A (left) RC9 24 and 115 volt ac output
stops.
Circuit Breaker CB6 protects the 24 volt
and 115 volt ac output to Welder B (right) re-
mote receptacle RC8. If CB6 opens, Weld-
er B (right) RC8 24 and 115 volt ac output
stops.
These fuses protect the weld stator wind-
ings. If fuse F11, F12, or F13 opens, Welder
B (right) side output is erratic or low. If fuse
F21, F22, or F23 opens, Welder A (left) side
output is erratic or low.
Open front panel.
Fuse F1 protects the exciter excitation
winding. If F1 opens, there is no weld or
generatorpower output on both sides.
10 Thermostats TP3 And TP4 (Internal −
Not Shown)
Thermostat TP3 protects Welder A (left)
SR2 rectifier and TP4 protects Welder B
(right) SR3 rectifier from overheating. If
TP3 or TP4 opens, Welder A (left) or Welder
B (right) weld output stops and the High
Temp. Shutdown light goes on. Wait fifteen
minutes for module to cool and thermostat
to automatically reset. Reduce amperage,
voltage, or duty cycle before welding.
Fuse F2 protects the exciter main field ex-
citation winding. If F2 opens, there is no
weld output on both sides.
Circuit Breaker CB7 protects field current
regulator board PC4. If CB7 opens, weld
and generator power output on both sides
stops.
Fuse F3 protects Welder A (left) control
board PC1. If F3 opens, Welder A (left) weld
output stops.
Circuit Breaker CB8 protects the generator
field flashing circuit. If CB8 opens, weld and
Fuse F4 protects Welder B (right) control
OM-494 Page 41
Download from Www.Somanuals.com. All Manuals Search And Download.
8-11. Troubleshooting
A. Welding
Trouble
Remedy
No weld output on either side; generator Place Output (Contactor) switches in On (Hot) position, or place switches in Remote position and connect
power output okay at ac receptacles.
Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP3 and
Check position of Process Selector switches and Welder Selector switch. All weld output stops if
either Process Selector switch is placed in CV position when Welder Selector switch is in Welder B
check field current regulator board PC4.
Have Factory Authorized Service Agent check field current regulator board PC4 and Welder Selector
switch S2.
No weld output on either side and no Disconnect equipment from generator power receptacles during start-up.
generator power output at ac recep-
tacles.
Have Factory Authorized Service Agent check brushes and slip rings, field excitation circuit, rotor, stator,
and field current regulator board PC4.
No Welder A (left) weld output; Welder B
(right) weld output okay.
Check position of Welder Selector switch. Welder A (left) weld output stops when Welder Selector
Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP3 to
Have Factory Authorized Service Agent check Welder A (left) contactor circuit.
No Welder B (right) weld output; Welder
A (left) weld output okay;
Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP4 to
Have Factory Authorized Service Agent check Welder B (right) contactor circuit.
er B (right) output okay.
Increase Amperage/Voltage control setting.
Check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have Factory Authorized
Service Agent check main rectifier SR2.
Have Factory Authorized Service Agent check main rectifier SR2, synchronization transformers T5,
T6 and T7, and control board PC1.
Low Welder B (right) weld output;
Welder A (left) weld output okay.
Increase Amperage/Voltage control setting.
Check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have Factory Authorized
Service Agent check main rectifier SR3.
Have Factory Authorized Service Agent check main rectifier SR3, synchronization transformers T8,
T9 and T10, and control board PC5.
OM-494 Page 42
Download from Www.Somanuals.com. All Manuals Search And Download.
Trouble
Remedy
Low weld output on both sides.
Increase Amperage/Voltage controls settings.
Have Factory Authorized Service Agent check field current regulator board PC4.
Have Factory Authorized Service Agent check field current regulator board PC4.
High weld output on both sides.
Erratic weld output on either side.
Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Check Process Selector switch(s) connections and contacts.
Welder A (left) side: check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have
Factory Authorized Service Agent check main rectifier SR2.
Welder B (right) side: check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have
Factory Authorized Service Agent check main rectifier SR3.
Have Factory Authorized Service Agent check Welder Selector switch S2.
Low open-circuit voltage on both sides. Check engine speed, and adjust if necessary (see Section 8-5).
Have Factory Authorized Service Agent check field current regulator board PC4.
Low open-circuit voltage on either side. Increase Amperage/Voltage control setting.
Welder A (left) side: check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have
Factory Authorized Service Agent check main rectifier SR2.
Welder B (right) side: check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have
Factory Authorized Service Agent check main rectifier SR3.
Have Factory Authorized Service Agent check main rectifiers SR2 and SR3, synchronization trans-
formers T5 thru T10, and control board PC1 or PC5.
No control of weld output on either
side.
Place A/V Control switch in Panel position, or place switch in Remote position and connect remote
Have Factory Authorized Service Agent check control board PC1 or PC5.
No voltage control on either side; open- Repair or replace remote device.
circuit voltage present.
Place A/V Control switch in Panel position, or place switch in Remote position and connect remote
Check connections to Remote receptacle RC8 and RC9.
Have Factory Authorized Service Agent check control board PC1 or PC5.
Wire feeder does not work (either side). Reset Welder A (left) circuit breaker CB5 or Welder B (right) circuit breaker CB6 (see Section 8-10).
Check position of Process Selector switches and Welder Selector switch. All weld output stops if
either Process Selector switch is placed in CV position when Welder Selector switch is in Welder B
Place optional Polarity switches in Reverse position. There is no CV weld output when Polarity switch
is in Straight position.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Repair or replace wire feeder.
OM-494 Page 43
Download from Www.Somanuals.com. All Manuals Search And Download.
B. Generator Power
Trouble
Remedy
tacles.
Check receptacle(s) for continuity and proper connections. Replace receptacle(s) if necessary.
Have Factory Authorized Service Agent check brushes and slip rings.
High or low output at generator power ac Check engine speed, and adjust if necessary (see Section 8-5).
receptacles.
C. Engine
Trouble
Remedy
Check battery voltage, and replace battery if necessary.
Check battery connections and tighten if necessary.
Have Factory Authorized Service Agent check Engine Start Button PB1.
Engine will not crank.
Engine cranks but does not start.
Check battery voltage, and replace battery if necessary.
Check blower fan V-belt according to engine manual. Safety shutdown stops engine if belt is broken or
Check engine charging system according to engine manual.
See engine manual.
Engine suddenly stops.
Check blower fan V-belt according to engine manual. Safety shutdown stops engine if belt is broken or
See 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).
Replace battery.
Check voltage regulator and connections according to engine manual.
wetstacking occurs.
OM-494 Page 44
Download from Www.Somanuals.com. All Manuals Search And Download.
Notes
OM-494 Page 45
Download from Www.Somanuals.com. All Manuals Search And Download.
210 657-A
OM-494 Page 47
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 10 − RUN-IN PROCEDURE
run_in3 8/01
10-1. Wetstacking
Y
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
1
Welding Generator
Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
2
. Do not idle engine longer than
necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generatoris kept loaded during
run-in.
1
2
Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for addition-
al engine run-in information.
OM-494 Page 48
Download from Www.Somanuals.com. All Manuals Search And Download.
10-2. Run-In Procedure Using Load Bank
Y
Y
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y
Y
Keep exhaust and pipe away
from flammables.
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
4
1
Load Bank
2
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
1
2
Welding Generator
Place Welder Selector switch in
Welder B position (600 Amps), A/V
control in minimum position, and
both Process Selector switches in
Stick/TIG position.
3
Weld Cables
Connect load bank to generator
Welder B (right) weld output termi-
nals using proper size weld cables
with correct connectors. Observe
correct polarity.
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator A/V control so load
equals 350 Amps at 40 volts.
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generatoris loaded properly.
3
.
C
h
e
c
k
o
i
l
l
e
v
e
l
f
r
e
q
u
e
n
t
l
y
d
u
r
-
ing run-in; add oil if needed.
After one hour (minimum) place A/V
control in minimum position, then
turn off load bank to remove load.
Run engine several minutes at no
load.
Y
Stop engine and let cool.
4
Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0683
OM-494 Page 49
Download from Www.Somanuals.com. All Manuals Search And Download.
10-3. Run-In Procedure Using Resistance Grid
Y
Y
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y
Y
Keep exhaust and pipe away
from flammables.
6
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
2
1
Resistance Grid
Use grid sized for generator rated
output.
Turn Off grid.
1
2
Welding Generator
Place Welder Selector switch in
Welder B position (600 Amps), A/V
control in minimum position, and
both Process Selector switches in
Stick/TIG position.
3
Weld Cables
Connect grid to generator Welder B
(right) weld output terminals using
proper size weld cables with cor-
rect connectors (polarity is not im-
portant).
4
5
Voltmeter
Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
5
3
Start engine and run for several
minutes.
Set grid switches and then adjust
generator A/V control so load
equals 350 Amps at 40 volts.
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
4
.
C
h
e
c
k
o
i
l
l
e
v
e
l
f
r
e
q
u
e
n
t
l
y
d
u
r
-
+
ing run-in; add oil if needed.
After one hour (minimum), place
A/V control in minimum position,
then shut down grid to remove load.
Run engine several minutes at no
load.
Y
Stop engine and let cool.
6
Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
OM-494 Page 50
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 11 − GENERATOR POWER GUIDELINES
The views in this section are intended to be representative of all engine-driven
welding generators. Your unit may differ from those shown.
NOTE
11-1. Selecting Equipment
1
Generator Power Receptacles
− Neutral Bonded To Frame
2
3-Prong Plug From Case
Grounded Equipment
3
2-Prong Plug From Double
Insulated Equipment
Y
Do not use 2-prong plug un-
less equipment is double in-
sulated.
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577
11-2. Grounding Generator To Truck Or Trailer Frame
Y
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
1
2
3
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
1
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
2
GND/PE
Y
If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.
3
Electrically bond generator
frame to vehicle frame by
metal-to-metalcontact.
Y
Bed liners, shipping skids, and some running
gear insulate the welding generator from the ve-
hicle frame. Always connect a ground wire from
the generator equipment grounding terminal to
bare metal on the vehicle frame as shown.
S-0854
OM-494 Page 51
Download from Www.Somanuals.com. All Manuals Search And Download.
11-3. Grounding When Supplying Building Systems
1
2
EquipmentGrounding
Terminal
1
2
Grounding Cable
GND/PE
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Y
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Use ground device as stated
in electrical codes.
2
3
ST-800 576-B
11-4. How Much Power Does Equipment Require?
1
Resistive Load
3
A light bulb is a resistive load and
requires a constant amount of power.
VOLTS 115
AMPS 4.5
Hz 60
2
2
Non-Resistive Load
1
Equipment with a motor is a non-re-
sistive load and requires approxi-
mately six times more power while
starting the motor than when running
3
Rating Data
3
Rating shows volts and amperes, or
watts required to run equipment.
AMPERES x VOLTS = WATTS
EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirementin watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-494 Page 52
Download from Www.Somanuals.com. All Manuals Search And Download.
11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Rating
Starting Watts
Running Watts
Split Phase
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
Capacitor Start-Induction Run
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
1-1/2 HP
2 HP
3 HP
5 HP
Capacitor Start-Capacitor Run
Fan Duty
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
550
650
800
1100
11-6. Approximate Power Requirements For Farm/Home Equipment
Farm/HomeEquipment
Stock Tank De-Icer
Rating
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
Grain Cleaner
1/4 HP
1/2 HP
3/4 HP
Portable Conveyor
Grain Elevator
1000
1400
1100
2800
720
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1-1/2 HP
2 HP
3 HP
5 HP
High Torque (e.g. Barn
1-1/2 HP
5 HP
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
1400
1600
800
Refrigerator or Freezer
Shallow Well Pump
1/3 HP
1/2 HP
1/3 HP
1/2 HP
750
1000
800
Sump Pump
1050
OM-494 Page 53
Download from Www.Somanuals.com. All Manuals Search And Download.
11-7. Approximate Power Requirements For Contractor Equipment
Contractor
Rating
Starting Watts
Running Watts
Hand Drill
1/4 in
3/8 in
350
400
350
400
1/2 in
600
600
Circular Saw
Table Saw
6-1/2 in
7-1/4 in
8-1/4 in
9 in
500
500
900
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
1400
1500
1800
1100
720
10 in
Band Saw
14 in
Bench Grinder
6 in
8 in
1400
1600
1000
1500
2200
2800
1100
1100
350
10 in
Air Compressor
1/2 HP
1 HP
1-1/2 HP
2 HP
Electric Chain Saw
Electric Trimmer
Electric Cultivator
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
500
500
2100
400
700
Elec. Hedge Trimmer
Flood Lights
18 in
400
HID
125
100
Metal Halide
Mercury
Sodium
Vapor
313
250
1000
1400
1250
600
1000
200
Submersible Pump
Centrifugal Pump
Floor Polisher
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
900
500
4500
6100
3150
4500
6100
1900
900
1400
1600
950
High Pressure Washer
3/4 HP
1400
1600
700
1 HP
55 gal Drum Mixer
Wet & Dry Vac
1/4 HP
1.7 HP
900
2-1/2 HP
1300
1300
OM-494 Page 54
Download from Www.Somanuals.com. All Manuals Search And Download.
11-8. Power Required To Start Motor
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
4
AC MOTOR
VOLTS 230 AMPS 2.5
Hz 60
PHASE 1
2
1
3
CODE
HP
M
1/4
Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiplyrunning amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amper-
age (see example).
Welding generator amperage out-
put must be at least twice the
motor’s running amperage.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A
Starting the motor requires 12.2 amperes.
230
S-0624
11-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.
2
5 Second Rule
1
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
2
Ref. ST-800 396-A / S-0625
OM-494 Page 55
Download from Www.Somanuals.com. All Manuals Search And Download.
11-10. Typical Connections To Supply Standby Power
Y
Properly install and ground this equipment according to
its Owner’s Manual and national, state, and local codes.
1
2
3
4
Fused
Disconnect
Switch
Utility
Electrical
Service
Welding
Generator
Output
Transfer Switch
(If Required)
5
Essential
Loads
Y
Y
Have only qualified persons perform Switch transfers the electrical load from Connect generator with temporary or perma-
these connections according to all electric utility service to the generator. Trans- nent wiring suitable for the installation.
applicable codes and safety practic- fer load back to electric utility when service is
Turn off or unplug all equipment connected to
generator before starting or stopping engine.
When starting or stopping, the engine has
low speed which causes low voltage and
frequency.
es.
restored.
Properly install and ground this Install correct switch (customer-supplied).
equipment according to its Owner’s Switch rating must be same as or greater
than the branch overcurrent protection.
Manual and national, state, and local
codes.
3 Fused Disconnect Switch
5 Essential Loads
. Customer-supplied equipment is re-
quired if generator will supply standby
power during emergencies or power out-
ages.
Install correct switch (customer-supplied) if
required by electrical code.
Generatoroutput may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
4 Welding Generator Output
Generator output voltage and wiring must be requirements, connect only essential loads
1 Utility Electrical Service
consistent with regular (utility) system volt- (pumps, freezers, heaters, etc. − See Sec-
2 Transfer Switch (Double-Throw)
age and wiring.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-494 Page 56
Download from Www.Somanuals.com. All Manuals Search And Download.
11-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
Y
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
4
6
8
10
12
14
5
600
350 (106)
250 (76)
175 (53)
112 (34)
87 (26)
62 (19)
50 (15)
50 (15)
37 (11)
225 (68)
150 (46)
112 (34)
75 (23)
50 (15)
37 (11)
37 (11)
137 (42)
100 (30)
62 (19)
37 (11)
30 (9)
100 (30)
62 (19)
50 (15)
30 (9)
7
840
400 (122)
275 (84)
175 (53)
137 (42)
112 (34)
87 (26)
10
15
20
25
30
35
40
45
50
1200
1800
2400
3000
3600
4200
4800
5400
6000
400 (122)
300 (91)
225 (68)
175 (53)
150 (46)
125 (38)
112 (34)
100 (30)
87 (26)
75 (23)
62 (19)
62 (19)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
Y
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
4
6
8
10
12
14
5
1200
1680
2400
3600
4800
6000
7000
8400
9600
10,800
12,000
700 (213)
500 (152)
350 (107)
225 (69)
175 (53)
125 (38)
100 (31)
100 (31)
75 (23)
450 (137)
300 (91)
225 (69)
150 (46)
100 (31)
75 (23)
225 (84)
200 (61)
125 (38)
75 (23)
200 (61)
125 (38)
100 (31)
60 (18)
7
800 (244)
550 (168)
350 (107)
275 (84)
225 (69)
175 (53)
150 (46)
125 (38)
125 (38)
100 (31)
10
15
20
25
30
35
40
45
50
800 (244)
600 (183)
450 (137)
350 (107)
300 (91)
250 (76)
225 (69)
200 (61)
175 (53)
60 (18)
75 (23)
*Conductor size is based on maximum 2% voltage drop
OM-494 Page 57
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 12 − PARTS LIST
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.
21
20
19
22
23
5
6
7
24
8
9
4
25−SEE FIG 12-4
18
10
17
3
11
16
28
12
13
9
2
27
26
1
15
14
103
10
30
10
9
31
96−SEE FIG 12-2
32
33
102
101
34
35
36
37
38
98
99
100
83
95
97
84
85
94
86
87
89
88
90
91
92
93
Figure 12-1. Main Assembly
OM-494 Page 58
Download from Www.Somanuals.com. All Manuals Search And Download.
50
48
47
49
46
45
44
51
43
52
53
54
46
40
55
39
56
41
58
57−SEE FIG 12-3
59
42
60
82
81
61
63
64
80
79
34
62
35
65
67
66
68
69
78−SEE FIG 12-4
36
70
37
71
77
76
75
74
72
73
802 317-D
OM-494 Page 59
Download from Www.Somanuals.com. All Manuals Search And Download.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
. . 1 . . . . . . . . . . . . . 605 288 . . FITTING, pipe galv plug sqhd .250NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . 070 010 . . BOLT, J stl .250-20 x 2.750 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 3 . . . . . . . . . . . . . 088 696 . . STRAP, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 4 . . . . . . . . . . . . . 134 771 . . PLUG, protective .640sq . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 5 . . . . . . . . . . . . . 184 675 . . TANK, fuel 22.3gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . 182 022 . . . . CAP, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . 020 185 . . FITTING, pipe brs elbow st 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . 053 525 . . FITTING, hose brs barbed M 5/16tbg x 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . 172 071 . . CLAMP, hose .520-.605clp dia slfng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 10 . . . . . . . . . . . . 134 835 . . HOSE, SAE .312 ID x .560 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . 9ft
. . 11 . . . . . . . . . . . . 097 507 . . STRIP, rbr adh back .125 x 1.000 x 20.500 60 duro . . . . . . . . . . . . . . . . . . . . 2
. . 12 . . . . . . . . . . . . 175 432 . . VALVE, shut-off fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . 039 599 . . FITTING, brs barbed M 5/16 tbg x 1/4 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . +048 227 . . UPRIGHT, base front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . 170 689 . . FRAME, mtg reactor and fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . +170 617 . . UPRIGHT, base center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . 017 479 . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . R3, R5 . . . 097 459 . . RESISTOR, WW fxd 375W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 20 . . . . . . . . . . . . 182 276 . . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . 208 353 . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . . . . . . . . 032 453 . . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 23 . . . . . . . . . . . . 190 896 . . BATTERY, stor 12v 660 crk 110 rsv gp 24 low . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . . . . . . . . 010 460 . . STUD, stl .312-18 x 10.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 25 SR2, SR3 Figure 12-5 . . RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 26 . . . . . . . . . . . . 176 697 . . LABEL, fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . . . . . . . . . . 145 282 . . FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT . . . . . . . . . . . . . . . . 2
. . 28 . . . . . . . . . . . . 083 859 . . BRACKET, mtg fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 30 . . . . . . . . . . . . 202 242 . . BASE, fuel filter assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 31 . . . . . . . . . . . . 192 744 . . SEPARATOR, fuel filter & water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . . . . . . . . . . . 135 205 . . NUT, 625-11 .94 hex .76H stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . 33 . . . . . . . . . . . . 116 707 . . SUPPORT, front engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 34 . . . . . . . . . . . . 119 849 . . SCREW, 625-11 x 4.00 hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 35 . . . . . . . . . . . . 071 731 . . WASHER, flat stl .656 ID x 2.250 OD x .187thk . . . . . . . . . . . . . . . . . . . . . . . 4
. . 36 . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 37 . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 38 . . . . . . . . . . . . 072 848 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 50 dur . . . . . . . . . . . . . . 2
. . 39 . . . . . . . . . . . . 010 875 . . CLAMP, muffler 2.000 dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 40 . . . . . . . . . . . . 105 734 . . PIPE, muffler extension elbow 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . 176 232 . . BAFFLE, air muffler exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 42 . . . . . . . . . . . . 048 216 . . BRACKET, mtg breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 43 . . . . . . . . . . . +105 909 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 44 . . . . . . . . . . . . 107 990 . . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 45 . . . . . . . . . . . . 035 968 . . WASHER, flat rbr 3.625 ID x 5.875 OD x .062thk . . . . . . . . . . . . . . . . . . . . . . 1
. . 46 . . . . . . . . . . . . 158 610 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 47 . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 48 . . . . . . . . . . . +192 313 . . DOOR, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 49 . . . . . . . . . . . . 108 487 . . LABEL, warning falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 50 . . . . . . . . . . . . 117 257 . . PANEL, end engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 51 . . . . . . . . . . . +192 314 . . DOOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 52 . . . . . . . . . . . . 181 642 . . LABEL, diesel engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 53 . . . . . . . . . . . . 004 130 . . BRACKET, support door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 54 . . . . . . . . . . . . 087 341 . . BUMPER, door 1.000 OD x .750 high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 55 . . . . . . . . . . . . 087 336 . . LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 56 . . . . . . . . . . . . 027 434 . . LABEL, welder will not start by applying power to terminals . . . . . . . . . . . . . 2
. . 57 . . . . . . . . . Figure 12-3 . . SIDE CONTROL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 58 . . . . . . . . . . . . 023 313 . . CLAMP, hose 3.250-3.000 clp dia slftg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 59 . . . . . . . . . . . . 201 547 . . HOSE, air cleaner w/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 60 . . . . . . . . . . . . 010 863 . . CLAMP, hose 2.062 − 3.000 clp slftg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-494 Page 60
Download from Www.Somanuals.com. All Manuals Search And Download.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . 61 . . . . . . . . . . . . 189 764 . . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *192 938 . . FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . *♦192 939 . . FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 203 462 . . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 62 . . . . . . . . . . . . 165 785 . . HOSE, air cleaner 2.437 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 63 . . . . . . . . . . . . 048 213 . . BAFFLE, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 194 467 . . WASHER, flat (for baffle) 6.25 ID x 11.50 OD x .62 T buna . . . . . . . . . . . . . 1
. . 64 . . . . . . . . . . . . . . . . . . . . . . . LEVER, trip shutdown (included w/engine − see engine parts list) . . . . . . . 1
. . 65 . . . . . . . . . . . . . . . . . . . . . . . SPRING (included w/engine − see engine parts list) . . . . . . . . . . . . . . . . . . . 1
. . 66 . . . . . . . . . . . . 181 634 . . ENGINE, dsl electric (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 67 . . . . . . . . . . . . 087 371 . . . . ROD, shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *064 677 . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *062 342 . . FILTER, fuel primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *064 686 . . FILTER, fuel secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *064 690 . . BELT, blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 68 . . . . . . . . . . . . 070 661 . . ROD, speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 69 . . . . . . . . . . . . 151 969 . . SWITCH, pressure 4PSI N/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 70 . . . . . . . . . . ♦047 361 . . FITTING, banjo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 71 . . . . . . . . . . ♦089 351 . . FITTING, pipe brs plug hexhd 1/2NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 72 . . . . . . . . . . ♦192 197 . . BRACKET, mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 73 . . . . . . . . . . . ♦008 114 . . HOSE, oil w/fittings 17.500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 74 . . . . . . . . . . ♦047 234 . . BOLT, banjo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦047 235 . . WASHER, oil seal copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 75 . . . . . . . . . . . . 127 994 . . BALL JOINT, .250-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 76 . . . . . . . . . . . . 162 740 . . STUD, stl .250-28 x 45.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 77 . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 60 dur . . . . . . . . . . . . . . 2
. . 78 . . . . . . . . . Figure 12-4 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 79 . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 80 . . . . . . . . . . . . 176 236 . . BAFFLE, air outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 81 . . . . . . . . . . . . . . . . . . . . . . . CLAMP, muffler (included with engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 82 . . . . . . . . . . . . 105 733 . . PIPE, muffler extension elbow 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 83 . . . . . . . . . . . . 165 739 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 84 . . . . . . . . . . . . 191 446 . . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . . . 2.1ft
. . 85 . . . . . . . . . . . . 173 352 . . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . 2.4ft
. . 86 . . . . . . . . . . . . 192 305 . . TRAY, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 87 . . . . . . . . . . . . 176 167 . . NUT, 250-20 acorn nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 88 . . . . . . . . . . . . 192 303 . . ANGLE, mtg stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 89 . Z1, Z2 . . . 192 296 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 90 . . . . . . . . . . . . 205 791 . . BRACKET, mtg fuse assembly (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 91 . . . . . . . . . . . . 204 965 . . . . STRIP, insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 92 . . . . . . . . . . . . . 026947 . . . . STAND-OFF, insul .250-20 x 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . 93 F11-13, F21-23 . 027 267 . . FUSE, link 300 A 250 volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 94 . . . . . . . . . . . . 192 304 . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 95 . . . . . . . . . . . . 134 792 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 96 . . . . . . . . . Figure 12-2 . . FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 97 . . . . . . . . . . . . 175 256 . . INSULATOR, side rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 98 . . . . . . . . . . . . 192 300 . . SHROUD, generator LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 99 . T2, T4 . . . 192 371 . . TRANSFORMER, 115V pri 24VCT 8A w/leads . . . . . . . . . . . . . . . . . . . . . . . . 2
. 100 . . . . . . . . . . . . 192 301 . . SHROUD, generator RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 101 . . . . . . . . . . . . 168 829 . . TRANSDUCER, current 1000A module max open loop . . . . . . . . . . . . . . . . 2
. 102 . . . . . . . . . . . . 192 299 . . SHROUD, generator center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 103 . . . . . . . . . . . . 194 021 . . CAPACITOR ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . 162 817 . . . . BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . C15, C20 . . 163 535 . . . . CAPACITOR, elctlt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . R4, R6 . . . 140 002 . . . . RESISTOR, WW fxd 10W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 162 799 . . . . BRACKET, mtg capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OM-494 Page 61
Download from Www.Somanuals.com. All Manuals Search And Download.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . . 193 501 . . KIT, label (includes safety and informational labels) . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label
individually or as part of Label Kit 193 501
*Recommended Spare Parts.
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.
6
7
8
9
5
4
2
12
1
13
14
11
10
15
16
42
28
22
13
29
41
27
26
30
12
21
18
24
17
40
39
25
2
23
18
22
20
19
35
36
30
21
37
38
31
34
32
33
802 318-C
Figure 12-2. Front Panel
OM-494 Page 62
Download from Www.Somanuals.com. All Manuals Search And Download.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . 1 . . . . . . . . . . . . . . 209056 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 2 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 3 . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 4 . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and serial number) . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . 190 375 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . . 216270 . . PANEL, aux power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 192 334 . . HARNESS, wiring aux power panel (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . 7 . GFCI1,2 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . . . 2
. . 8 . . CB1-4 . . . 093 996 . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . . . 4
. . 9 . RC1, RC2 . . 193 257 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 250V . . . . . . . . . . . . . . . . . . . . . . 2
. . 10 . . R10 . . . . 189 699 . . RESISTOR, WW tap 375W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . 038 620 . . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 12 . TE1,2 . . . . 038 621 . . BLOCK, term 30A 4 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 13 . T5 - 10 . . . 210 636 . . TRANSFORMER, control 6VA 120VCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 14 . . PC4 . . . . 191 255 . . CIRCUIT CARD ASSEMBLY, field current regulator . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . 083 147 . . GROMMET, SCR NO 8/10 panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 16 . . . . . . . . . . . . 192 332 . . PANEL LAYOUT, mtg component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . CB7,8 . . . . 139 266 . . CIRCUIT BREAKER, man reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 18 . . 1T,2T . . . . 190 210 . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . . . . . . . . . . . 083 030 . . STUD, brs .250-20 x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . 010 381 . . CONNECTOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . T1, T3 . . . 192 367 . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 22 . . . . . . . . . . . . 184 649 . . HOLDER, fuse mintr .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 23 . . F3,4 . . . *012 643 . . FUSE, mintr gl slo-blo 1A, 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 24 . . F1,2 . . . *125 847 . . FUSE, mintr cer slo-blo 12A, 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 25 . . . . . . . . . . . . 129 351 . . SCREW, 008−32x .50 hexwhd.34d stl pld slffmg tap−rw . . . . . . . . . . . . . . . . 2
. . 26 . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . C1 . . . . . 087 110 . . CAPACITOR, elctlt 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . SR1 . . . . 035 704 . . RECTIFIER, integ bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 195 702 . . HARNESS, wiring componet panel (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 188 512 . . . . . SEAL, wire univ 6P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . 187 651 . . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . RC13,21 . . 116 045 . . . . . HOUSING, plugs and pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG17 . . . 135 275 . . . . . HOUSING, plugs and pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . RC19, PLG20 . 168 071 . . . . . HOUSING, plugs and pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . S2 . . . . . 192 292 . . SWITCH, paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 192 006 . . HARNESS, engine (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 30 . . PB1 . . . . 046 433 . . . . SWITCH, PB MC NO SPST 35A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 31 . . . . . . . . . . . . . . . . . . . . . . . STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . . HM . . . . . 145 247 . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . . . . . . . . . . 205 744 . . ROD, engine shutoff assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 34 . . . . . . . . . . . . 019 603 . . KNOB, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 35 . . PL1 . . . . . 188 266 . . LIGHT, ind red lens 13V (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 36 . . . . . . . . . . . . 082 788 . . . . HOLDER, light ind only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 37 . . . . . . . . . . . . 048 155 . . . . BULB, incand min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 38 . . . . . . . . . . . . 082 789 . . . . LENS, light ind red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 40 . . . . . . . . . . . . 111 785 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and serial number) . . . . . . . . . 1
. . 42 . . . . . . . . . . . . 192 316 . . PANEL, front control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label
individually or as part of Label Kit 193 501
*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-494 Page 63
Download from Www.Somanuals.com. All Manuals Search And Download.
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.
1
31
32
30
29
33
2
34
28
27
26
7
8
6
5
3
4
9
10
11
25
13
24
14
23
35
22
36
21
15
12
16
20
18
19
17
802 320-A
Figure 12-3. Side Control Panels − Welder B (Right) Side Shown
OM-494 Page 64
Download from Www.Somanuals.com. All Manuals Search And Download.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . 1 . . . . . . . . . . . . +192 330 . . PANEL, side output RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . +192 325 . . PANEL, side output LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . 027 434 . . LABEL, welder will not start by applying power to terminals . . . . . . . . . . . . . 2
. . 3 . . . . . . . . . . . . . 010 828 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 4 . . . . . . . . . . . . . 086 074 . . TUBING, cop .540 ID x .123 wall x .562 − welder A (left) side only . . . . . . . 1
. . 5 . . S1, S9 . . . 204 903 . . SWITCH, mode single w/ dust cover (consisting of) . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . 163 557 . . . . SWITCH, mode single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 202 881 . . . . COVER, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . 193 337 . . ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 7 . . . PC5 . . . . 204 832 . . CIRCUIT CARD ASSEMBLY, welder B (right) side control . . . . . . . . . . . . . . 1
. . . . . . . . PC1 . . . . 204 835 . . CIRCUIT CARD ASSEMBLY, welder A (left) side control . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 192 218 . . HARNESS, wiring control box welder B (right) (consisting of) . . . . . . . . . . . 1
. . 8 . . . CR3 . . . . 000 770 . . . . RELAY, encl 24VDC 3PDT 10A/120VAC 11 pin . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . GRD . . . . 185 011 . . . . STUD, primary board brs 10-32 x 1.592 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 S8,10,11 . . 011 609 . . . . SWITCH, tgl SPDT 15A 125VAC on-none-on . . . . . . . . . . . . . . . . . . . . . . . 3
. . 11 . . R7,8 . . . . 035 897 . . . . POTENTIOMETER, cp std slot 1t 2w 1k linear . . . . . . . . . . . . . . . . . . . . . . 2
. . 12 . LS3, 4 . . . 089 645 . . . . SWITCH, lim 11A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG27 . . . 131 056 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 187 651 . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG20 . . . 168 071 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG9,26 . . 148 439 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG12 . . . 152 249 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG10 . . . 153 501 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC22 . . . . 168 845 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC23 . . . . . 168846 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG8 . . . . 169 240 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 192 208 . . HARNESS, wiring control box welder A (left) (consisting of) . . . . . . . . . . . . 1
. . . . . . . . CR2 . . . . 000 770 . . . . RELAY, encl 24VDC 3PDT 10A/120VAC 11 pin . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . GRD . . . . 185 011 . . . . STUD, primary board brs 10-32 x 1.592 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . S3,6,7 . . . 011 609 . . . . SWITCH, tgl SPDT 15A 125VAC on-none-on . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . R1,8 . . . . 035 897 . . . . POTENTIOMETER, cp std slot 1t 2w 1k linear . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . LS1,2 . . . . 089 645 . . . . SWITCH, lim 11A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG18 . . . 131 056 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 187 651 . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG19 . . . 168 071 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG4,11 . . 148 439 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG5 . . . . 152 249 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG10 . . . 153 501 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC6 . . . . 168 845 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC7 . . . . . 168846 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG3 . . . . 169 240 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 PC2, PC6 . . 178 130 . . CIRCUIT CARD ASSEMBLY, digital meter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 14 . . . . . . . . . . . . 165 316 . . STAND-OFF, No. 6-32 x .875 lg .312 hex nyl . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . 136 343 . . SCREW, K50 x 20 soc hd trx stl pld slftpg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . 15 . . . . . . . . . . . . 097 924 . . KNOB, pointer 1.625dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 16 . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 17 . . . . . . . . . . . . 097 922 . . KNOB, pointer .875dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 18 . . . . . . . . . . . . 148 956 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . 2
. . 20 . . . . . . . . . . . . 162 815 . . PANEL, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 21 . . . . . . . . . . . . 161 297 . . CAM, switch selector 2posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 22 . . . . . . . . . . . . 170 391 . . CONNECTOR, circ protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 23 . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . 039 049 . . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 039 044 . . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 601 976 . . . . SCREW, 500-13 x 1.50 hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 601 880 . . . . NUT, 500-13 x .75 hex .31H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-494 Page 65
Download from Www.Somanuals.com. All Manuals Search And Download.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-3. Side Control Panels (Continued)
. . 24 . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . 039 045 . . . . TERMINAL BOARD, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 039 044 . . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 601 976 . . . . SCREW, 500-13 x 1.50 hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 601 880 . . . . NUT, 500-13 x .75 hex .31H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 25 . . . . . . . . . . . . 192 494 . . BUS BAR, connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 26 . . . . . . . . . . . . 192 493 . . STAND-OFF, bus bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 27 C2,4,5,21,22,23 . 136 736 . . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . 192 336 . . HARNESS, wiring unit welder B (right) (consisting of) . . . . . . . . . . . . . . . . . . 1
. . 28 . . . 4T . . . . . 190 210 . . . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . CB6 . . . . 139 266 . . . . CIRCUIT BREAKER, man reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 30 . . RC9 . . . . 134 735 . . . . CONNECTOR, circ MS/CPC 14skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 31 . . PC7 . . . . 181 261 . . . . CIRCUIT CARD ASSEMBLY, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG24 . . . 115 094 . . . . HOUSING, plug and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG22 . . . 168 847 . . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG23 . . . 152 249 . . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG21 . . . 135 556 . . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 188 512 . . . . SEAL, wire univ 6P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 192 337 . . HARNESS, wiring unit welder A (left) (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . 3T . . . . . 190 210 . . . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB5 . . . . 139 266 . . . . CIRCUIT BREAKER, man reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC8 . . . . 134 735 . . . . CONNECTOR, circ MS/CPC 14skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PC3 . . . . 181 261 . . . . CIRCUIT CARD ASSEMBLY, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG14 . . . 115 094 . . . . HOUSING, plug and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG6 . . . . 168 847 . . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG3 . . . . 152 249 . . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG13 . . . 135 556 . . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 188 512 . . . . SEAL, wire univ 6P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . . . . . . . . . . . 165 316 . . STAND-OFF, No. 6-32 x .875 lg .312 hex nyl . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . 145 217 . . SCREW, K40 x 12 pan hd phl stl pld slftpg . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 33 . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 34 . . . . . . . . . . ♦010 647 . . PIN, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . ♦091 067 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . ♦168 077 . . CONNECTOR, tw lk insul fem (Dinse-type) to output stud . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . ♦199 123 . . LABEL, component identification master polarity . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦199 124 . . LABEL, component identification slave polarity . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 35 PL2, PL3 . . 159 522 . . LED, yellow 2.1v 20 ma 45.0 mcd panel mtg .250 hole . . . . . . . . . . . . . . . . . 2
. . 36 . . . . . . . . . . . . 159 036 . . LENS, led clear panel mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label
individually or as part of Label Kit 193 501
*Recommended Spare Parts.
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-494 Page 66
Download from Www.Somanuals.com. All Manuals Search And Download.
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.
Ref. 048 456-E
Figure 12-4. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . 1 . . . . . . . . . . . . *151 299 . . BRUSH, contact elect clrg .375 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 2 . . . . . . . . . . . . . 188 387 . . BRUSHHOLDER/BRACKET ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . . 600 270 . . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 4 . . . . . . . . . . . . . 152 044 . . . . CAP, holder brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 5 . . . . . . . . . . . . . 173 066 . . . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . +205 600 . . STATOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . . 039 207 . . . . BAFFLE, air generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . . 192 286 . . ROTOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . 024 617 . . . . RING, retaining external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . 053 390 . . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . 083 748 . . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OM-494 Page 67
Download from Www.Somanuals.com. All Manuals Search And Download.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-4. Generator (Continued)
. . 13 . . . . . . . . . . . . 195 704 . . STATOR, exciter aux pwr 120/240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . 173 068 . . ENDBELL, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . 143 220 . . . . O-RING 2.859ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label
individually or as part of Label Kit 193 501
*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.
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.
1
802 319
Figure 12-5. Rectifier Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . 1 . . . . . . . . . . . . . 205 613 . . RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 203 001 . . RECTIFIER, Si Diode (One Side Service kit W/Varnish Coating) . . . . . . . . 1
. . . . . PLG1, PLG2 . 158 720 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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-494 Page 68
Download from Www.Somanuals.com. All Manuals Search And Download.
Notes
OM-494 Page 69
Download from Www.Somanuals.com. All Manuals Search And Download.
Download from Www.Somanuals.com. All Manuals Search And Download.
Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
*
*
*
*
*
*
Induction Heating Coils and Blankets
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
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.
Canvas Covers
Your distributor also gives
you ...
Miller’s True Blue Limited Warranty shall not apply to:
Service
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
*
Original main power rectifiers
Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
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.
*
*
*
*
Water Coolant Systems (Integrated)
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
3. 1 Year — Parts and Labor Unless Specified
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
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 BY 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.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
*
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches
miller_warr 1/05
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
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
2005 Miller Electric Mfg. Co. 1/05
Download from Www.Somanuals.com. All Manuals Search And Download.
|