Big Blue 502D

OM-495 192 774AR
October 2003
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)

Cutting and Gouging
Description
Engine Driven Welding Generator
Big Blue 402D, 502D, 602D

And Non-CE Models
Visit our website at

www.MillerWelds.com
More user manuals on ManualsBase.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard. particular model are also provided.
Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 7/03

TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 7
2-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Warning Label Definitions (For Wordless Labels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Manufacturer’s Rating Labels For Non-CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-3. Manufacturer’s Rating Labels For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-4. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-3. Volt-Ampere Curves For CC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-4. Volt-Ampere Curves For CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-5. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-7. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-8. Optional Three-Phase Generator Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-1. Installing Welding Generator (See Sections 5-2 And 5-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-2. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-5. Installing Engine Side Baffle (CE Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-6. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-7. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-8. Installing Optional Ether Cylinder (Deutz F3L912 Engine Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-9. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-10. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5-11. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5-12. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models . . . . . . . . . . . . . . . . . . . . . 32
5-13. Connecting To Remote 14 Receptacle RC14 On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-1. Front Panel Controls For CC Models (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-3. Remote Amperage Control On CC Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6-4. Weld Control/Arc Condition Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

TABLE OF CONTENTS
SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7-1. Front Panel Controls For CC/CV Models (See Section 7-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) . . . . . . . . . . . . . . . . . . . . . . 39
7-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 8 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-1. Generator Power Receptacles (Standard Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-2. Connecting To Optional Three-Phase Generator (CC/CV Standard Models Only) . . . . . . . . . . . . . . . . 43
8-3. Optional Generator Power Receptacles (Standard Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8-4. Generator Power Receptacles (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SECTION 9 − MAINTENANCE (DEUTZ F4L2011−POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9-1. Routine Maintenance (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9-3. Servicing Air Cleaner (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . 50
9-5. Adjusting Engine Speed (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9-6. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . . . . 52
9-7. Overload Protection (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SECTION 10 − MAINTENANCE (DEUTZ F3L912−POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10-1. Routine Maintenance (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10-3. Servicing Air Cleaner (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . 58
10-5. Adjusting Engine Speed (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10-6. Servicing Optional Ether Starting Aid (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10-7. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . 60
10-8. Overload Protection (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SECTION 11 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11-1. Diagnosing Causes Of Engine Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11-2. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SECTION 13 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
13-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
13-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
13-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SECTION 14 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
SECTION 15 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
OPTIONS AND ACCESSORIES
WARRANTY

Declaration of Conformity for
European Community (CE) Products
NOTE This information is provided for units with CE certification (see rating label on unit).
Manufacturer’s Name: Miller Electric Mfg. Co.

Manufacturer’s Address: 1635 W. Spencer Street
Appleton, WI 54914 USA
Declares that the product: Big Blue 602D (Deutz F4L1011-Powered Models)
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Machinery Directives: 98/37/EEC,91/368/EEC, 93/C 133/04, 93/68/EEC
Noise level of Welding Generators: 2000/14/EC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Standards
Safety Requirements for Arc Welding Equipment IEC 60974-1: 1998-09
Rotating Electrical Machines − Part 1: Rating and Performance: IEC 34-1: 1994
Rotating Electrical Machines − Part 5: Classification of degrees of protection provided by enclosure of rotating
electrical machines (IP code): IEC 34-5: 1991
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and test: IEC 60664-1: 2000-04
Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995
European Contact: Mr. Danilo Fedolfi, Managing Director

ITW WELDING PRODUCTS ITALY S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Telephone: 39(02)98290-1
Fax: 39(02)98290-203
dec_con1 _11/02

Declaration of Conformity for
European Community (CE) Products
NOTE This information is provided for units with CE certification (see rating label on unit).
Manufacturer’s Name: Miller Electric Mfg. Co.

Manufacturer’s Address: 1635 W. Spencer Street
Appleton, WI 54914 USA
Declares that the product: Big Blue 602D (Deutz F4L1011-Powered Models)
conforms to the following Directives and Standards relating to sound levels:
Directives
Noise Level Of Welding Generators: 2000/14/EC
Sound Level Information

Measured Sound Power Level: 98 dB
Guaranteed Sound Power Level: 98 dB
This equipment conforms to requirements brought forth by 2000/14/EC
Noise conformity assessment procedure followed with notified body:
AV Technology Limited
AVTECH House
Birdhall Lane
Cheadle Heath
Stockport
Cheshire
SK3OXU
Sound power level requirements determined by the 40% duty cycle of 600 A, 30 V
Conforming assessment procedure 1 of Annex VI will be followed.
European Contact: Mr. Danilo Fedolfi, Managing Director

MILLER Europe S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Telephone: 39(02)98290-1
Fax: 39(02)98290203
dec_con1 5/98

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom _nd_10/02
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.
Marks a special safety message.

This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
Means “Note”; not safety related. to avoid the hazards.
1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual to Use only well-maintained equipment. Repair or replace damaged parts at
call attention to and identify possible hazards. When you see the once. Maintain unit according to manual.
symbol, watch out, and follow the related instructions to avoid the Wear a safety harness if working above floor level.
hazard. The safety information given below is only a summary of
Keep all panels and covers securely in place.
the more complete safety information found in the Safety Stan-
dards listed in Section 1-7. Read and follow all Safety Standards. Clamp work cable with good metal-to-metal contact to workpiece or work-
table as near the weld as practical.
Only qualified persons should install, operate, maintain, and re- Insulate work clamp when not connected to workpiece to prevent contact
pair this unit. with any metal object.
During operation, keep everybody, especially children, away. Do not connect more than one electrode or work cable to any single weld
output terminal.
SIGNIFICANT DC VOLTAGE exists in inverters after stop-
ELECTRIC SHOCK can kill.
ping engine.
Stop engine on inverter and discharge input capacitors according to
Touching live electrical parts can cause fatal shocks or
instructions in Maintenance Section before touching any parts.
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 FUMES AND GASES can be hazardous.
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. Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
Do not touch live electrical parts.
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
Insulate yourself from work and ground using dry insulating mats or covers fumes and gases.
big enough to prevent any physical contact with the work or ground.
If ventilation is poor, use an approved air-supplied respirator.
Do not use AC output in damp areas, if movement is confined, or if there is a Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
danger of falling. instructions for metals, consumables, coatings, cleaners, and degreasers.
Use AC output ONLY if required for the welding process. Work in a confined space only if it is well ventilated, or while wearing an air-
If AC output is required, use remote output control if present on unit. supplied respirator. Always have a trained watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury
Additional safety precautions are required when any of the following electri- or death. Be sure the breathing air is safe.
cally hazardous conditions are present: in damp locations or while wearing
Do not weld in locations near degreasing, cleaning, or spraying operations.
wet clothing; on metal structures such as floors, gratings, or scaffolds;
The heat and rays of the arc can react with vapors to form highly toxic and
when in cramped positions such as sitting, kneeling, or lying; or when there
irritating gases.
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order present- Do not weld on coated metals, such as galvanized, lead, or cadmium plated
ed: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual steel, unless the coating is removed from the weld area, the area is well
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most ventilated, and if necessary, while wearing an air-supplied respirator. The
situations, use of a DC, constant voltage wire welder is recommended. coatings and any metals containing these elements can give off toxic fumes
And, do not work alone! if welded.
Disconnect input power or stop engine before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29 CFR BUILDUP OF GAS can injure or kill.
1910.147 (see Safety Standards).
Properly install and ground this equipment according to its Owner’s Manual Shut off shielding gas supply when not in use.
and national, state, and local codes. Always ventilate confined spaces or use approved
air-supplied respirator.
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.
When making input connections, attach proper grounding conductor first −
double-check connections.
Arc rays from the welding process produce intense visible
Frequently inspect input power cord for damage or bare wiring — replace and invisible (ultraviolet and infrared) rays that can burn eyes
cord immediately if damaged — bare wiring can kill. and skin. Sparks fly off from the weld.
Turn off all equipment when not in use. Wear a welding helmet fitted with a proper shade of filter to protect your face
Do not use worn, damaged, undersized, or poorly spliced cables. and eyes from arc rays and sparks when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
Do not drape cables over your body. Wear approved safety glasses with side shields under your helmet.
If earth grounding of the workpiece is required, ground it directly with a sep- Use protective screens or barriers to protect others from flash and glare;
arate cable. warn others not to watch the arc.
Do not touch electrode if you are in contact with the work, ground, or anoth- Wear protective clothing made from durable, flame-resistant material (wool
er electrode from a different machine. and leather) and foot protection.
Return To Table Of Contents OM-495 Page 1

WELDING can cause fire or explosion. HOT PARTS can cause severe burns.
Welding on closed containers, such as tanks, drums, or Allow cooling period before maintaining.
pipes, can cause them to blow up. Sparks can fly off from the Wear protective gloves and clothing when working on
welding arc. The flying sparks, hot workpiece, and hot a hot engine.
equipment can cause fires and burns. Accidental contact of electrode to metal Do not touch hot engine parts or just-welded parts
objects can cause sparks, explosion, overheating, or fire. Check and be sure bare-handed.
the area is safe before doing any welding.
Protect yourself and others from flying sparks and hot metal. NOISE can damage hearing.
Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can damage
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not hearing.
possible, tightly cover them with approved covers.
Wear approved ear protection if noise level is high.
Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.

MAGNETIC FIELDS can affect pacemakers.
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause Pacemaker wearers keep away.
fire on the hidden side. Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
Do not weld on closed containers such as tanks, drums, or pipes, unless tions.
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 CYLINDERS can explode if damaged.
causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes. Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
Remove stick electrode from holder or cut off welding wire at contact tip normally part of the welding process, be sure to treat them
when not in use. carefully.
Wear oil-free protective garments such as leather gloves, heavy shirt, cuf- Protect compressed gas cylinders from excessive heat, mechanical
fless trousers, high shoes, and a cap. shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary support or
Remove any combustibles, such as a butane lighter or matches, from your cylinder rack to prevent falling or tipping.
person before doing any welding.
Keep cylinders away from any welding or other electrical circuits.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
Never drape a welding torch over a gas cylinder.
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-
FLYING METAL can injure eyes. signed for the specific application; maintain them and associated parts in
good condition.
Welding, chipping, wire brushing, and grinding cause
Turn face away from valve outlet when opening cylinder valve.
sparks and flying metal. As welds cool, they can
throw off slag. Keep protective cap in place over valve except when cylinder is in use or
Wear approved safety glasses with side shields even connected for use.
under your welding helmet. Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
1-3. Engine Hazards
BATTERY EXPLOSION can BLIND. MOVING PARTS can cause injury.

Always wear a face shield, rubber gloves, and protec- Keep away from fans, belts, and rotors.
tive clothing when working on a battery. Keep all doors, panels, covers, and guards closed
Stop engine before disconnecting or connecting bat- and securely in place.
tery cables or servicing battery.
Stop engine before installing or connecting unit.
Do not allow tools to cause sparks when working on a battery.
Have only qualified people remove guards or covers for maintenance
Do not use welder to charge batteries or jump start vehicles. and troubleshooting as necessary.
Observe correct polarity (+ and −) on batteries. To prevent accidental starting during servicing, disconnect negative (−)
Disconnect negative (−) cable first and connect it last. battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving parts.
FUEL can cause fire or explosion. Reinstall panels or guards and close doors when servicing is finished
and before starting engine.
Stop engine and let it cool off before checking or add- Before working on generator, remove spark plugs or injectors to keep
ing fuel. engine from kicking back or starting.
Do not add fuel while smoking or if unit is near any Block flywheel so that it will not turn while working on generator compo-
sparks or open flames. nents.
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-495 Page 2 Return To Table Of Contents

STEAM AND HOT COOLANT can burn. BATTERY ACID can BURN SKIN and EYES.
If possible, check coolant level when engine is cold to Do not tip battery.
avoid scalding. Replace damaged battery.
Always check coolant level at overflow tank, if pres- Flush eyes and skin immediately with water.
ent on unit, instead of radiator (unless told otherwise
in maintenance section or engine manual).
If the engine is warm, checking is needed, and there is no overflow tank,
follow the next two statements. ENGINE HEAT can cause fire.
Wear safety glasses and gloves and put a rag over radiator cap.
Do not locate unit on, over, or near combustible
Turn cap slightly and let pressure escape slowly before completely re- surfaces or flammables.
moving cap.
Keep exhaust and exhaust pipes way from flam-
mables.
ENGINE EXHAUST GASES can kill. EXHAUST SPARKS can cause fire.
Use equipment outside in open, well-ventilated ar-
Do not let engine exhaust sparks cause fire.
eas.
Use approved engine exhaust spark arrestor in re-
If used in a closed area, vent engine exhaust outside
quired areas — see applicable codes.
and away from any building air intakes.
1-4. Compressed Air Hazards
BREATHING COMPRESSED AIR can HOT METAL from air arc cutting and
cause serious injury or death. gouging can cause fire or explosion.
Do not use compressed air for breathing. Do not cut or gouge near flammables.
Use only for cutting, gouging, and tools. Watch for fire; keep extinguisher nearby.
COMPRESSED AIR can cause injury. HOT PARTS can cause burns and injury.
Wear approved safety goggles. Do not touch hot compressor or air system parts.
Do not direct air stream toward self or others. Let system cool down before touching or servicing.
TRAPPED AIR PRESSURE AND WHIPPING

READ INSTRUCTIONS.
HOSES can cause injury.
Read Owner’s Manual before using or servicing unit.
Release air pressure from tools and system before
servicing, adding or changing attachments, or open- Stop engine and release air pressure before
ing compressor oil drain or oil fill cap. servicing.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING.

Use lifting eye to lift unit only, NOT running gear, gas Allow cooling period; follow rated duty cycle.
cylinders, trailer, or any other accessories. Reduce current or reduce duty cycle before starting
Use equipment of adequate capacity to lift and to weld again.
support unit. Do not block or filter airflow to unit.
If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
OVERHEATING can damage motors. STATIC (ESD) can damage PC boards.

Turn off or unplug equipment before starting or stop-
ping engine. Put on grounded wrist strap BEFORE handling
boards or parts.
Do not let low voltage and frequency caused by low
engine speed damage electric motors. Use proper static-proof bags and boxes to store,
move, or ship PC boards.
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.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with proper Use tongue jack or blocks to support weight.
guards in a safe location wearing proper face, hand, Properly install welding generator onto trailer accord-
and body protection. ing to instructions supplied with trailer.
Sparks can cause fires — keep flammables away.

READ INSTRUCTIONS. ARC WELDING can cause interference.
Use only genuine MILLER/Hobart replacement Electromagnetic energy can interfere with sensitive
parts. electronic equipment such as microprocessors,
Perform engine and air compressor (if applicable) computers, and computer-driven equipment such as
maintenance and service according to this manual robots.
and the engine/air compressor (if applicable) manu- Be sure all equipment in the welding area is electro-
als. magnetically compatible.
To reduce possible interference, keep weld cables as short as possible,
H.F. RADIATION can cause interference. close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic
High-frequency (H.F.) can interfere with radio naviga- equipment.
tion, safety services, computers, and communica- Be sure this welding machine is installed and grounded according to this
tions equipment. manual.
Have only qualified persons familiar with electronic If interference still occurs, the user must take extra measures such as
equipment perform this installation. moving the welding machine, using shielded cables, using line filters, or
The user is responsible for having a qualified electrician shielding the work area.
promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at
once.
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

Welding or cutting equipment produces fumes or gases which For Gasoline Engines:
contain chemicals known to the State of California to cause Engine exhaust contains chemicals known to the State of
birth defects and, in some cases, cancer. (California Health & California to cause cancer, birth defects, or other reproductive
Safety Code Section 25249.5 et seq.) harm.
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of Diesel engine exhaust and some of its constituents are known
California to cause cancer and birth defects or other to the State of California to cause cancer, birth defects, and
reproductive harm. Wash hands after handling. other reproductive harm.
1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 in Toronto 416-747-4044, website: www.csa-international.org).
(phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11
ting of Containers and Piping, American Welding Society Standard West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi- website: www.ansi.org).
ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire Protec- Standard for Fire Prevention During Welding, Cutting, and Other Hot
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, from National Fire Protection Association,
02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
sparky.org). 617-770-3000, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, OSHA, Occupational Safety and Health Standards for General Indus-
from Compressed Gas Association, 1735 Jefferson Davis Highway, try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website: and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
www.cganet.com). intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
Code for Safety in Welding and Cutting, CSA Standard W117.2, from are 10 Regional Offices—phone for Region 5, Chicago, is
Canadian Standards Association, Standards Sales, 178 Rexdale Bou- 312-353-2220, website: www.osha.gov).
1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency To reduce magnetic fields in the workplace, use the following
Electric And Magnetic Fields procedures:
1. Keep cables close together by twisting or taping them.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such 2. Arrange cables to one side and away from the operator.
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from
Research Council concluded that: “The body of evidence, in the operator as practical.
committee’s judgment, has not demonstrated that exposure to power- 5. Connect work clamp to workpiece as close to the weld as
frequency electric and magnetic fields is a human-health hazard.”
possible.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you About Pacemakers:
may wish to minimize your exposure to electromagnetic fields when Pacemaker wearers consult your doctor first. If cleared by your doctor,
welding or cutting. then following the above procedures is recommended.

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 8/03
Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.
2-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure Ce groupe de symboles si-
présente des risques de danger ! Ceux-ci sont identifiés par gnifie Mise en garde !
des symboles adjacents aux directives.
Soyez vigilant ! Il y a des
risques de danger reliés
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-
Signifie NOTA ; n’est pas relatif à la sécurité. sous afin de connaître les mesures à prendre pour éviter tout danger.
2-2. Dangers relatifs au soudage à l’arc

Les symboles présentés ci-après sont utilisés tout au long du En effectuant les raccordements d’entrée fixer d’abord le conducteur de
présent manuel pour attirer votre attention et identifier les ris- mise à la terre approprié et contre-vérifier les connexions.
ques de danger. Lorsque vous voyez un symbole, soyez Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas en-
vigilant et suivez les directives mentionnées afin d’éviter tout dommagé ou dénudé − remplacer le cordon immédiatement s’il est
danger. Les consignes de sécurité présentées ci-après ne font endommagé − un câble dénudé peut provoquer une électrocution.
que résumer l’information contenue dans les normes de sécu- Mettre l’appareil hors tension quand on ne l’utilise pas.
rité énumérées à la section 2-6 . Veuillez lire et respecter toutes Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
ces normes de sécurité. mal épissés.
Ne pas enrouler les câbles autour du corps.
L’installation, l’utilisation, l’entretien et les réparations ne
Si la pièce soudée doit être mise à la terre, le faire directement avec un
doivent être confiés qu’à des personnes qualifiées.
câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour.
Au cours de l’utilisation, tenir toute personne à l’écart et plus Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
particulièrement les enfants. une électrode provenant d’une autre machine.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
UN CHOC ÉLECTRIQUE peut tuer. manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Un simple contact avec des pièces électriques peut Maintenir solidement en place tous les panneaux et capots.
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec
que l’appareil est sur ON. Le circuit d’entrée et les circuits la pièce à souder ou la table de travail, le plus près possible de la soudure.
internes de l’appareil sont également sous tension à ce
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
logement des galets d’entraînement et les pièces métalliques en contact avec avec tout objet métallique.
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la Une tension DC importante subsiste à l’intérieur
terre présentent un danger.
des onduleurs après avoir coupé l’alimentation.
Ne jamais toucher les pièces électriques sous tension. Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des compo-
Porter des gants et des vêtements de protection secs ne comportant pas
sants.
de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens iso- LES FUMÉES ET LES GAZ peuvent
lants suffisamment grands pour empêcher le contact physique éventuel être dangereux.
avec la pièce ou la terre.
Ne pas se servir de source électrique àcourant électrique dans les zones Le soudage génère des fumées et des gaz. Leur inhalation
humides, dans les endroits confinés ou là où on risque de tomber. peut être dangereux pour votre santé.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande. Eloigner votre tête des fumées. Ne pas respirer les fumées.
Si l’utilisation d’une source électrique àcourant électrique s’avère néces- À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de
saire, se servir de la fonction de télécommande si l’appareil en est équipé. l’arc pour l’évacuation des fumées et des gaz de soudage.
Des précautions de sécurité supplémentaires sont requises dans des envi- Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
ronnements à risque comme: les endroits humides ou lorsque l’on porte
des vêtements mouillés; sur des structures métalliques au sol, grillages et Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-
tions du fabricant concernant les métaux, les consommables, les
échafaudages; dans des positions assises, à genoux et allongées; ou
revêtements, les nettoyants et les dégraisseurs.
quand il y a un risque important de contact accidentel avec la pièce ou le
Travailler dans un espace fermé seulement s’il est bien ventilé ou en por-
sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence:
tant un respirateur à alimentation d’air. Demander toujours à un surveillant
1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
poste à souder manuel (électrode enrobée) DC, 3) un poste à souder ma- peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des
nuel AC avec tension à vide réduite. Dans la plupart des cas, un poste blessures ou des accidents mortels. S’assurer que l’air de respiration ne
courant continu de type CV est recommandé. Et, ne pas travailler seul! présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de dé-
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 graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
Installer et mettre à la terre correctement cet appareil conformément à son
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvani-
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si néces-
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre saire, en portant un respirateur à alimentation d’air. Les revêtements et
du sectionneur ou que la fiche du cordon est raccordée à une prise tous les métaux renfermant ces éléments peuvent dégager des fumées
correctement mise à la terre. toxiques en cas de soudage.

Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B
LES ACCUMULATIONS DE GAZ ris- pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi-
quent de provoquer des blessures ou mité.
même la mort.
DES PARTICULES VOLANTES
Fermer l’alimentation du gaz protecteur en cas de peuvent blesser les yeux.
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- Le soudage, l’écaillement, le passage de la pièce
rateur d’adduction d’air homologué. à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques vo-
LES RAYONS DE L’ARC peuvent pro- lantes. Pendant la période de refroidissement des soudures, elles ris-
quent de projeter du laitier.
voquer des brûlures dans les yeux et Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
sur la peau.
Le rayonnement de l’arc du procédé de soudage génère DES PIÈCES CHAUDES peuvent
des rayons visibles et invisibles intenses (ultraviolets et provoquer des brûlures graves.
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage. Prévoir une période de refroidissement avant d’effec-
Porter un casque de soudage muni d’un écran de filtre approprié pour pro- tuer des travaux d’entretien.
téger votre visage et vos yeux pendant le soudage ou pour regarder (voir Porter des gants et des vêtements de protection pour
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). travailler sur un moteur chaud.
Porter des protections approuvés pour les oreilles si le niveau sondre est Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
trop élevé. récemment soudées.
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-
Porter des protections approuvés pour les oreilles si
cendie ou une explosion. le niveau sondre est trop élevé.
Le soudage effectué sur des conteneurs fermés tels que LES CHAMPS MAGNÉTIQUES peuvent
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles peuvent être projetées de 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 Porteurs de stimulateur cardiaque, restez à distance.
accidentel de l’électrode avec des objets métalliques peut provoquer des Les porteurs d’un stimulateur cardiaque doivent
étincelles, une explosion, un surchauffement ou un incendie. Avant de d’abord consulter leur médecin avant de s’approcher
commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de des opérations de soudage à l’arc, de gougeage ou
danger. de soudage par points.
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Si des BOUTEILLES sont endomma-
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
gées, elles pourront exploser.
substances inflammables. Des bouteilles de gaz protecteur contiennent du gaz sous
Déplacer toutes les substances inflammables à une distance de 10,7 m de haute pression. Si une bouteille est endommagée, elle peut
l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec exploser. Du fait que les bouteilles de gaz font normale-
des protections homologués. ment partie du procédé de soudage, les manipuler avec
précaution.
Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
ouvertures. chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. arcs.
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé- Placer les bouteilles debout en les fixant dans un support stationnaire ou
clencher un incendie de l’autre côté. dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser- Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés électriques.
correctement conformément à AWS F4.1 (voir les normes de sécurité). Ne jamais placer une torche de soudage sur une bouteille à gaz.
Brancher le câble sur la pièce le plus près possible de la zone de soudage Une électrode de soudage ne doit jamais entrer en contact avec une bou-
pour éviter le transport du courant sur une longue distance par des che- teille.
mins inconnus éventuels en provoquant des risques d’électrocution et Ne jamais souder une bouteille pressurisée − risque d’explosion.
d’incendie.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. raccords convenables pour cette application spécifique; les maintenir ainsi
En cas de non utilisation, enlever la baguette d’électrode du porte-électro- que les éléments associés en bon état.
de ou couper le fil à la pointe de contact. Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
Porter des vêtements de protection dépourvus d’huile tels que des gants Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
en cuir, une chemise en matériau lourd, des pantalons sans revers, des ou de branchement de la bouteille.
chaussures hautes et un couvre chef. Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
Avant de souder, retirer toute substance combustible de vos poches telles les équipements associés et les publication P-1 CGA énumérées dans les
qu’un allumeur au butane ou des allumettes. normes de sécurité.
2-3. Dangers existant en relation avec le moteur
LES ACCUMULATIONS DE GAZ ris- L’ACIDE DE LA BATTERIE peut pro-

quent de provoquer des blessures ou voquer des brûlures dans les YEUX et
même la mort. sur la PEAU.
Fermer l’alimentation du gaz protecteur en cas de Ne pas renverser la batterie.
non utilisation. Remplacer une batterie endommagée.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- Rincer immédiatement les yeux et la peau à l’eau.
rateur d’adduction d’air homologué.

Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,
L’EXPLOSION DE LA BATTERIE peut débrancher le câble négatif (−) de batterie de la borne.
RENDRE AVEUGLE. Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga-
nes mobiles.
Toujours porter une protection faciale, des gants en Remettre en place les panneaux ou les dipositifs de protection et fermer les
caoutchouc et vêtements de protection lors d’une in- portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.
tervention sur la batterie. Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en
Arrêter le moteur avant de débrancher ou de brancher les câbles de route accidentelle du moteur.
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
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhi- REFROIDISSEMENT CHAUD peuvent
cules de démarrage rapide.
Observer la polarité correcte (+ et −) sur les batteries.
provoquer des brûlures.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier Il est préférable de vérifier le liquide de
lieu. refroidissement une fois le moteur refroidi pour éviter
de se brûler.
LE CARBURANT MOTEUR peut pro-
Toujours vérifier le niveau de liquide de refroidissement dans le vase d’ex-
voquer un incendie ou une explosion. pansion (si présent), et non dans le radiateur (sauf si précisé autrement
dans la section maintenance du manuel du moteur).
Arrêter le moteur avant de vérifier le niveau de carbu-
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme sui-
rant ou de faire le plein.
vant :
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.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-
rant renversé avant de faire démarrer le moteur. LA CHALEUR DU MOTEUR peut pro-
Jeter les chiffons dans un récipient ignifuge. voquer un incendie.
DES ORGANES MOBILES peuvent Ne pas placer l’appareil sur, au-dessus ou à proximité
provoquer des blessures. de surfaces inflammables.
Tenir à distance les produits inflammables de
Ne pas approcher les mains des ventilateurs, cour- l’échappement.
roies et autres pièces en mouvement.
Maintenir fermés et fixement en place les portes, LES ÉTINCELLES À L’ÉCHAPPEMENT
panneaux, recouvrements et dispositifs de peuvent provoquer un incendie.
protection.
Arrêter le moteur avant d’installer ou brancher l’appareil. Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
Demander seulement à un personnel qualifié d’enlever les dispositifs de
Utiliser uniquement un pare-étincelles approuvé −
sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’en-
voir codes en vigueur.
tretien et de dépannage.
2-4. Dangers liés à l’air comprimé

RESPIRER L’AIR COMPRIMÉ peut pro- Le METAL CHAUD lors du coupage et
voquer des blessures graves ou causer gougeage plasma peut provoquer un in-
la mort. cendie ou une explosion.
Ne pas utiliser l’air comprimé pour respirer. Ne pas couper ou gouger à proximité de produits
Utiliser l’air comprimé seulement pour le coupa- inflammables.
ge, gougeage et les outils pneumatiques. Surveillez et garder un extincteur à proximité.
L’AIR COMPRIMÉ peut provoquer DES PIECES CHAUDES peuvent provo-

des blessures. quer des brûlures et blessures.
Porter des lunettes de sécurité approuvées.
Ne pas diriger le jet d’air vers d’autres ou soi− Ne pas toucher le compresseur ou d’autres élé-
même. ments du circuit air comprimé chauds.
Laisser l’ensemble se refroidir avant de toucher
L’AIR COMPRIME EMMAGASINE ET DES ou d’effectuer la maintenance.
TUYAUX SOUS PRESSION peuvent provo-
quer des blessures. LIRE LES INSTRUCTIONS.
Relâcher la pression d’air de l’outillage ou du sys-
tème avant d’effectuer la maintenance, avant de Lisez le manuel d’instructions avant l’utilisation
changer ou de rajouter des éléments ou avant ou la maintenance de l’appareil.
d’ouvrir la purge ou le bouchon de remplissage Arrêter le moteur et relâcher la pression avant
d’huile. d’effectuer la maintenance.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la

maintenance
Utiliser un équipement de levage de capacité suffisante pour lever
LA CHUTE DE L’APPAREIL peut l’appareil.
blesser. En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
Utiliser l’anneau de levage uniquement pour soulever opposé de l’appareil.
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.

LE SURCHAUFFEMENT peut endom- LIRE LES INSTRUCTIONS.
mager le moteur électrique.
Utiliser seulement les pièces de rechange d’origine.
Arrêter ou déconnecter l’équipement avant de dé- Effectuer la maintenance du moteur et du compres-
marrer ou d’arrêter le moteur. seur (si applicable) suivant ce manuel et le manuel du
moteur/compresseur (si applicable).
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.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a LE RAYONNEMENT HAUTE FRÉ-
lieu. QUENCE (H.F.) risque de provoquer
LES ÉTINCELLES VOLANTES ris- des interférences.
quent de provoquer des blessures. Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements
Porter un écran facial pour protéger le visage et les de radio−navigation et de communication, les
yeux. services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées avec des
Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de pro- équipements électroniques de faire fonctionner l’installation.
tecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque
L’utilisateur est tenu de faire corriger rapidement par un électricien quali-
l’on porte l’équipement homologué de protection du visage, des mains et
fié les interférences résultant de l’installation.
du corps.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Les étincelles risquent de causer un incendie − éloigner toute substance
inflammable. Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des sources
L’EMPLOI EXCESSIF peut de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et et un blindage pour réduire les interférences
SURCHAUFFER L’ÉQUIPEMENT. éventuelles.
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de LE SOUDAGE À L’ARC risque de
poursuivre le soudage.
provoquer des interférences.
Ne pas obstruer les passages d’air du poste.
L’énergie électromagnétique risque de provoquer
LES CHARGES ÉLECTROSTATI- des interférences pour l’équipement électronique
QUES peuvent endommager les sensible tel que les ordinateurs et l’équipement com-
circuits imprimés. mandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible
Établir la connexion avec la barrette de terre avant de électromagnétiquement.
manipuler des cartes ou des pièces. 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-
Utiliser des pochettes et des boîtes antistatiques
sible (ex. par terre).
pour stocker, déplacer ou expédier des cartes de
circuits imprimes. Veiller à souder à une distance de 100 mètres de tout équipement élec-
tronique sensible.
UNE REMORQUE QUI BASCULE peut Veiller à ce que ce poste de soudage soit posé et mis à la terre conformé-
entraîner des blessures. ment à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il in-
Utiliser les supports de la remorque ou des blocs combe à l’utilisateur de prendre des mesures supplémentaires telles que
pour soutenir le poids. le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil-
Installer convenablement le poste sur la remorque tres de ligne ou la pose de protecteurs dans la zone de travail.
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 Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à To-
l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (télé- ronto : (416) 747−4044, site Web : www.csa−international.org).
phone : (305) 443−9353, site Web : www.aws.org). Practice For Occupational And Educational Eye And Face Protection,
Recommended Safe Practices for the Preparation for Welding and Cutting norme ANSI Z87.1, de l’American National Standards Institute, 11 West
of Containers and Piping, norme American Welding Society AWS F4.1, de 42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site
l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (télé- Web : www.ansi.org).
phone : (305) 443−9353, site Web : www.aws.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work,
National Electrical Code, norme NFPA 70, de la National Fire Protection As- norme NFPA 51B, de la National Fire Protection Association, P.O. Box
sociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617)
(téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org). 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de OSHA, Occupational Safety and Health Standards for General Industry,
la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web : Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent
www.cganet.com). of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Cana- régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site
dian Standards Association, Standards Sales, 178 boulevard Rexdale, Web : www.osha.gov).
2-7. Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnétiques Afin de réduire les champs électromagnétiques en milieu de travail, respec-
basse fréquence sur l’organisme ter les consignes suivantes :
En parcourant les câbles de soudage, le courant crée des champs électro- 1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
magnétiques. Les effets potentiels de tels champs restent préoccupants. ruban adhésif.
Cependant, après avoir examiné plus de 500 études qui ont été faites pen- 2. Mettre tous les câbles du côté opposé à l’opérateur.
dant une période de recherche de 17 ans, un comité de spécialistes du 3. Ne pas s’enrouler les câbles autour du corps.
National Research Council a conclu : « L’accumulation de preuves n’a pas 4. Garder le poste de soudage et les câbles le plus loin possible de soi.
démontré que l’exposition aux champs magnétiques et aux champs électri- 5. Placer la pince de masse le plus près possible de la zone de soudage.
ques à haute fréquence constitue un risque pour la santé humaine ». Consignes relatives aux stimulateurs cardiaques :
Toutefois, les études et l’examen des preuves se poursuivent. En attendant Les personnes qui portent un stimulateur cardiaque doivent avant tout
les conclusions finales de la recherche, il serait souhaitable de réduire l’ex- consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-
position aux champs électromagnétiques pendant le soudage ou le mandé de respecter les consignes ci-dessus.
coupage.

SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions (For Wordless Labels)
Warning! Watch Out! There are

possible hazards as shown by the
symbols.
Become trained and read the

instructions before working on the
machine or welding.
1 Electric shock from welding
electrode or wiring can kill.
1.1 Wear dry insulating gloves. Do
not touch electrode with bare
hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Do not work on unit if engine
is running. Stop engine first.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Do not weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding helmet
with correct shade of filter.
Wear complete body
protection.
5 Do not remove or paint over
(cover) the label.
6 Engine fuel plus flames or
sparks can cause fire.
6.1 Do not smoke while fueling or if
near fuel.
6.2 Stop engine before fueling.
6.3 Do not fuel a hot engine.
7 Engine exhaust gases can kill.
7.1 Vent exhaust outside.
7.2 Use unit outside.
3/96

1 2 3 4 5 6 1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Do not smoke and keep
matches and flames away from
battery.
3 Sparks can cause battery
10 gases to explode. Battery
explosion can blind and injure.
Wear a face shield.
4 1
+ − 4 4 Battery acid can burn skin. Do
1 not spill acid.
11 + − 5 Read Owner’s Manual.
+ − 6 Wear rubber gloves.
7 Dead battery
8 Engine block
3 2 9 Fully charged battery
2 3
10 Do not connect last negative
7 cable to dead battery − connect
+ − + − instead to engine block.
11 Jumper cables − observe
polarity and make connections
S-176 108
in numbered sequence shown.
12 Once dead battery is charged,
disconnect cables in sequence
8 9 12 shown. 3/96
1 1 Warning! Watch Out! There

2 2 Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
injury. Keep away from moving
parts.
S-176 106 3/96
Starting Aid Switch. Below 32°F (0°C),

push switch up for 60 seconds before
starting engine.
Starting Instructions:
1 Press and hold Magnetic
Shutdown switch.
2 Turn Engine Control switch to
Start position.
3 Release Engine Control switch
and Starting Aid switch (if used)
when engine starts.
4 Continue holding Magnetic
Shutdown switch for 3 seconds
after engine starts.

2 Hot muffler and exhaust pipes
can cause severe burns. Do
not touch hot muffler or pipes.
S-176 230
3/96

2 3 2 Engine fuel plus flames or
sparks can cause fire.
3 Do not smoke while fueling or if
near fuel.
4 Stop engine before fueling.
4 5 Do not fuel a hot engine.
5
6 Use Diesel Fuel only.
3/96
1
1 Warning! Watch Out! There
2 Falling equipment can cause
serious injury and damage.
3 Use lifting eye to lift or move
unit only. Use proper
equipment when lifting.
4 Do not use lifting eye to lift and
support unit and trailer or other
heavy devices or accessories.
S-176 104
2 3 4 3/96

1 2
2 Fire hazard from leaking
engine fuel. Fire can result from
welding on base at
non-designated areas causing
a possible fuel leak.
3 Fuel tank is located inside
base.
4 Do not weld on base of unit.
5 Weld only on supplied brackets
or bolt unit down.
3 4

1 2 Electric shock from wiring can
kill.
3 Moving parts, such as fans,
rotors, and belts, can cut
fingers and hands and cause
2 injury. Keep away from moving
parts.

1 Remove unit from shipping
S-177 571
crate. Remove Owner’s
1
+
Manual from unit. Follow
instructions to install muffler.
2 Read Owner’s Manual. Read
labels on unit.
2 3 Use Diesel Fuel only, and fill
+ 4
fuel tank. Leave room for
expansion.
Warning! Watch Out! There
3 shown by the symbols. Read
DIESEL Owner’s Manual. Follow
instructions to activate
battery.
4 5 Check oil level. Add oil if
necessary.
6 During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
5 7 After the first 50 hours of
operation, change the oil and
oil filter.
0 − 50 h Std. 200A 0 − 200A
50 h Std.
API CD-MIL L 2104D,

CD/SE, CD/SF
3/96
3-2. Manufacturer’s Rating Labels For Non-CE Products

CC Models CC/CV Models

3-3. Manufacturer’s Rating Labels For CE Products
CC Models CC/CV Models
MATERIAL THICKNESS REFERENCE CHART

Notes 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)

3-4. Symbols And Definitions
Fast (Run, Weld/

Stop Engine Slow (Idle) Start Engine
Power)
Engine Oil
Starting Aid Battery (Engine) Engine Oil
Pressure
Check Injectors/ Check Valve Protective Earth

Fuel
Pump Clearance (Ground)
Certified/Trained
Positive Negative Welding Arc
Mechanic
A Amperes
V Volts Panel/Local Remote
Air Temperature Or
Alternating
Engine Engine Output
Current
Temperature
Stick (SMAW) Constant Current MIG (GMAW)

TIG (GTAW)
Welding (CC) Welding
h s 1
Time Hours Seconds Single Phase
3
Read Operator’s Do Not Switch
Three Phase Circuit Breaker
Manual While Welding
Engine-Driven,
Electrode
Connection
Work Connection G
Three-Phase
Alternator With
Rectifier
Hz Hertz
X Duty Cycle U0 Rated No Load

Voltage (Average) U2 Conventional
Load Voltage
n
Rated Load
Speed
n1 Rated Idle
Speed n0 Rated No Load
Speed I Current I2 Rated Welding
Current
Contactor On

SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Weld Maximum
Welding Rated Welding Generator Power Fuel
Output Open-Circuit Engine
Mode Output Rating Capacity
Range Voltage
Deutz
F4L2011-Powered
55 − 600 A Units:
(CC Models)
400 A, 40 Volts DC, 95 Standard:
CC/DC 20 − 600 A 100% Duty Cycle Single-Phase,
(CC/CV 4 kVA/kW, 34/17 A,
500 A, 40 volts DC, DEUTZ
Models) 120/240 V AC, 50/60 Hz Deutz F4L2011
60% Duty Cycle
Three-Phase Generator Air/Oil-Cooled, Four
600 A, 30 Volts DC, 25 gal
Option:
Option:* Cylinder, 44 HP Diesel
40% Duty Cycle (95 L)
Single-Phase/Three-Phase, Engine
Deutz 12/20 kVA/kW, 50/48A, or
CV/DC F3L912-Powered 120/240 VAC, 60 Hz
Units: Deutz F3L912,
(CC/CV *In Addition To Standard Air-Cooled, Three
14 − 40 V 500 A, 40 volts DC, 56
Models 4 kVA/kW Generator Power Cylinder, 41.5 HP
Only) 100% Duty Cycle Diesel Engine
600 A, 30 Volts DC,
40% Duty Cycle
4-2. Dimensions, Weights, And Operating Angles
Dimensions
50 in (1270 mm)
Height
(to top of muffler)
28-1/2 in (724 mm) G

(mtg. brackets turned in)
Width Do not exceed tilt angles or engine could
30-3/4 in (781 mm) be damaged or unit could tip.
(mtg. brackets turned out)
Do not move or operate unit where it could
Depth 65-1/8 in (1654 mm) tip.
A 65-1/8 in (1654 mm)
B* 56 in (1422 mm)
C* 46-1/2 in (1181)
A
D* 9-5/8 in (244 mm) B C
E 27-1/2 in (699 mm)
F 1 in (25 mm)
30°
G 29-1/2 in (749 mm)
H 30°
H
9/16 in (14 mm) Dia. 20°
4 Holes
D 20°
* With mounting brackets in center Front Panel End
position. Dimensions vary with
location of mounting brackets.
F
Weight E
w/ Deutz No fuel: 1690 lb (767 kg)
F4L2011 w/fuel: 1880 lb (853 kg) 802 161
161-A
A 802 311
w/ Deutz No fuel: 1785 lb (810 kg)

F3L912 w/fuel: 1975 lb (896 kg)

4-3. Volt-Ampere Curves For CC Models
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
100 curves shown.
Ranges
300−Max
80 185−425
125−320
85−190
60
55−90
DC VOLTS
40
20
0
0 100 200 300 400 500 600 700 800 900
DC AMPERES
203 412
Notes

4-4. Volt-Ampere Curves For CC/CV Models
The volt-ampere curves show the
A. Stick Mode minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
100 other settings fall between the
Ranges curves shown.
80 300−Max
185−425
125−320
DC VOLTS
60 85−190
55−90
40
20
0
0 100 200 300 400 500 600 700 800 900
DC AMPERES
B. MIG Mode
100
80
60
DC VOLTS
MAX
40
20 MIN
0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
C. TIG Mode
100
Ranges
80 60−310
40−200
30−130
60 20−70
DC VOLTS
40
20
0
0 50 100 150 200 250 300 350 400 450 500
DC AMPERES 203 414 / 203 415 / 203 413

4-5. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
1800 RPM
IDLE
0
0 50 100 150 200 250 300 350 400 450 500
DC WELD AMPERES AT 100% DUTY CYCLE
193 093
Notes

4-6. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
Exceeding duty cycle can
A. Deutz F4L-1011-Powered Units damage unit and void
warranty.
100% Duty Cycle At 400 Amperes
Continuous Welding
B. Deutz F3L912-Powered Units
100% Duty Cycle At 500 Amperes
Continuous Welding
089 697-D / 202 356

4-7. AC Generator Power Curve
The ac power curve shows the gen-
erator power in amperes available
at the 120 and 240 volt receptacles.
150 300
125 250
AC VOLTS
100 200
75 150
50 100
25 50
0 0
0 5 10 15 20 25 30
AC AMPERES IN 240V MODE
0 10 20 30 40 50 60
AC AMPERES IN 120V MODE
193 018
Notes

4-8. Optional Three-Phase Generator Curves
The ac power curves show the gen-
erator power available in amperes
at the single-phase 120/240 volt re-
ceptacle or three-phase 240 volt
A. 12 kVA/kW Single-Phase AC Output (No Weld Load) terminals.
140 280
135 270
130 260
125 250
AC VOLTS
120 240
115 230
110 220
105 210
100 200
95 190
90 180
0 20 40 60 80 100
AC AMPERES
B. 20 kVA/kW Three-Phase AC Output (No Weld Load)
280
260
240
220
200
180
0 10 20 30 40 50 60 70
AC AMPERES
197 472 / 197 473

Notes
Start Your Professional 400 Trade Square East, Troy, Ohio 45373
Over 80,000 trained
Welding Career Now! 1-800-332-9448 www.welding.org since 1930!

SECTION 5 − INSTALLATION
5-1. Installing Welding Generator (See Sections 5-2 And 5-3)
Always securely fasten weld-
ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
Movement ble codes.
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
If unit does not have GFCI re-
ceptacles, use GFCI-protected
OR OR extension cord.
See Section 5-3 for mounting in-

formation.
Grounding:
1 Equipment Grounding Terminal
Location (On Front Panel)
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger insu-
OR OR lated copper wire.
Grounding
1
GND/PE 2
Electrically bond generator frame to

vehicle frame by metal-to-metal contact.
3 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.
Airflow Clearance
18 in
(460 mm)
18 in
18 in (460 mm)
(460 mm)
18 in
18 in (460 mm)
(460 mm)
install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274

5-2. Using Lifting Eye
1 Lifting Eye
2 Nut
1
3 Carriage Bolt
Raise lifting eye until it snaps in
place. Lower lifting eye when not
needed.
To lock the lifting eye in the upright
position, insert a 3/8-16 x 1-1/2 in
2 carriage bolt through slot in bracket
and secure with nut (bolt and nut not
supplied).
Tools Needed:
Ref. 802 169-B / 802 311
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

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

Bolting Unit In Place
3
2
Tools Needed:
9/16 in install3 5/02 803 274 / 190 250-A / 803 231

5-4. Installing Exhaust Pipe
Stop engine and let cool.
Point exhaust pipe in desired di-

rection but always away from
front panel and direction of travel.
Tools Needed:
1/2 in Ref. 802 169-E / Ref. 202 705
5-5. Installing Engine Side Baffle (CE Models Only)

Stop engine, and let cool.
1 Engine Side Baffle
(Part No. 212 570)
Loosen four screws securing en-
gine side panel.
Position side baffle over side panel.
Tighten screws.
Loosen upper and lower

panel mounting screws.
Ref. 803 353 / 803 372

5-6. Activating The Dry Charge Battery (If Applicable)
Remove battery from unit.
1 Eye Protection − Safety
Glasses Or Face Shield
2 Rubber Gloves
5 3 Vent Caps
4 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
4 5 Well
1 Fill each cell with electrolyte to
3 bottom of well (maximum).
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
Read and follow all instruc-
2 tions supplied with battery
charger.
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
maintain proper level.
5 A For 30 Minutes Tools Needed:
OR
+
− rubber gloves
30 A For 12 Minutes
glasses
drybatt1 1/98 − 0886

5-7. Connecting The Battery
Reinstall cover after connecting battery.
Connect Negative (−) Cable Last.

+
Tools Needed:
1/2 in 802 168-E / Ref. 202 705 / 802 313 / S-0756-C
5-8. Installing Optional Ether Cylinder (Deutz F3L912 Engine Only)

Stop engine.
Improper handling or expo-
sure to ether can harm your
health. Follow manufactur-
er’s safety instructions on
cylinder.
Do not use Ether Starting Aid
1 while engine is running.
Remove rubber access plug from
cover.
1 Ether Cylinder
2 Nozzle
Remove cover and clean cylinder
nozzle.
2 3 Clamp
4 Fitting
5 Cap
6 Valve
3 Remove cap and clean fitting.
Install cylinder on fitting. Tighten
4 clamp.
5 After installing cylinder, wait at

least 10 minutes before using
to let ether particles settle and
6 prevent atomizer plugging.
Put cap on fitting when cylinder is
removed.
Reinstall plug in cover.
ether1 7/96 − 153 382-A / Ref. 202 705

5-9. Engine Prestart Checks
Full
Diesel
Deutz F4L2011 Engine
Full
Full
Diesel
Deutz F3L912 Engine
Full
Ref. 802 313-A / 802 398-A

Check all engine fluids daily. If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 13.
Oil
After fueling, check oil with unit on level sur-
face. If oil is not up to full mark on dipstick,
Engine must be cold and on a level surface. add oil (see maintenance label).
Fuel
Unit is shipped with 20W break-in oil. The
Automatic shutdown system stops engine if To improve cold weather starting:
oil pressure is too low or coolant tempera- Do not use gasoline. Gasoline will Use optional Starting Aid switch (see
ture is too high. damage engine. Section 6-1 or 7-1).
Keep battery in good condition. Store

Add fresh diesel fuel before starting to pre-
This unit has a low oil pressure shut- vent air from entering the fuel system (see
battery in warm area.
down switch. However, some condi- engine maintenance label for fuel specifica-
Use fuel formulated for cold weather
tions may cause engine damage before tions). Leave filler neck empty to allow room
(diesel fuel can gel in cold weather).
the engine shuts down. Check oil level for expansion.
often and do not use the oil pressure Contact local fuel supplier for fuel in-
formation.
shutdown system to monitor oil level.
Do not run out of fuel or air may enter fuel
system and cause starting problems. See Use correct grade oil for cold weather
Follow run-in procedure in engine manual. engine manual to bleed air from fuel system. (see Section 9-2 or 10-2).

5-10. Connecting To Weld Output Terminals
Stop engine.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
For Stick and TIG welding Direct Current
Electrode Positive (DCEP), connect elec-
trode holder cable to Positive (+) terminal
on left and work cable to Negative (−) ter-
minal on right.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional polarity switch,
connect electrode holder cable to Elec-
trode terminal on left and work cable to
Work terminal on right.
For MIG and FCAW welding Direct Cur-
rent Electrode Positive (DCEP) on CC/CV
models, connect wire feeder cable to Pos-
itive (+) terminal on left and work cable to
Negative (−) terminal on right. Use Pro-
cess/Contactor switch to select type of
weld output (see Section 7-3).
1
For Direct Current Electrode Negative
Tools Needed: (DCEN), reverse cable connections.
If equipped with optional polarity switch,
3/4 in connect wire feeder cable to Electrode ter-
2
minal on left and work cable to Work termi-
nal on right. 802 311-A
5-11. Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Stop engine before 10 − 60% 60 − 100%
connecting to weld out- Welding
Duty Duty 10 − 100% Duty Cycle
put terminals. Amperes
Cycle Cycle
Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
2 ea. 2/0 2 ea. 2/0

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

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

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

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)
* Thischart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-E−
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

5-12. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models
1 Remote Amperage Adjust
Receptacle RC13
1
Connect optional remote control to
RC13 (see Section 6-3).
Ref. 154 862-A / 048 720-K / 802 311
5-13. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
Socket* Socket Information
A 24 volts ac. Protected by circuit

breaker CB5.
24 VOLTS AC
B Contact closure to A completes
24 volt ac contactor control
circuit.
C Output to remote control:+10

volts dc in MIG or Stick mode;
0 to +10 volts dc in TIG mode.
D Remote control circuit common.

New! LDR-14 long REMOTE
distance remote OUTPUT
(includes 120 V CONTROL E DC input command signal: 0 to
receptacle)
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
115 volts, 10 amperes, 60 Hz

I ac. Protected by circuit breaker
OR CB6.
115 VOLTS AC
Contact closure to I completes

J 115 volt ac contactor control
circuit.
K Chassis common.
802 311
GND
NEUTRAL G Circuit common for 24 and 115

volt ac circuit.
*The remaining sockets are not used.

Notes

SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS
6-1. Front Panel Controls For CC Models (See Section 6-2)

5 6
4 7
13 14 18 19 10 11 12
3 1
15 16
17
202 705 / 802 311-A

6-2. Description Of Front Panel Controls For CC Models (See Section 6-1)
Engine Starting Controls 5 Engine Temperature Light 13 Ampere Range Switch

1 Magnetic Shutdown Switch Light goes on and engine stops if engine oil Do not switch under load.
Use switch during start-up to bypass engine temperature is above 266 ° F (130° C).
shutdown system. System stops engine if oil Use switch to select weld amperage range.
Stop engine and fix trouble if Engine
pressure is too low or engine temperature is For most welding applications, use lowest
Temperature light goes on.
too high. amperage range possible to help prevent arc
6 Engine Oil Pressure Light outages (see Section 6-4).
2 Starting Aid Switch (Optional)
Light goes on and engine stops if oil pressure
Use switch to energize starting aid for cold 14 Amperage Adjust Control
is below 22 psi (150 kPa). Light goes on mo-
weather starting.
mentarily during start-up but goes out when Control adjusts amperage within range se-
Deutz F4L2011-powered units use a glow engine reaches normal oil pressure. lected by Ampere Range switch (see Section
plug starting aid. Push switch up for 60 sec- 6-4). Weld output would be about 223 A DC
onds to operate the glow plug before cranking Stop engine and fix trouble if Engine
Oil Pressure light stays on after start- with controls set as shown (50% of 125 to 320
engine (see starting instructions following). A).
up.
Deutz F3L912-powered units use an ether
starting aid system. Push switch up and re- 7 Fuel Light The numbers around the control are for
lease while cranking engine to release ether Fuel light is not active on this model. reference only and do not represent an
(see starting instructions following).
8 Engine Hour Meter actual percentage value.
3 Engine Control Switch
Engine Gauges 15 Stick/TIG Selection Switch
Use switch to start engine, select engine
speed (if unit has auto idle option), and stop To read gauges and engine indicator Use switch to disable the max OCV circuit
engine. lights with engine off, turn Engine Control and the arc drive (dig) circuit for scratch start
TIG welding (see max OCV note under Weld
In Run position, engine runs at weld/power switch to Run/Idle and press Magnetic
speed. In Run/Idle position (optional), engine Shutdown switch (see Section 11-1). Controls).
runs at idle speed at no load and weld speed 9 Fuel Gauge When switch is in the Stick position, the max
with load applied. OCV circuit resets Amperage Adjust Control
Use gauge to check fuel level. R1 to maximum when the arc breaks.
To Start:
To check fuel level when engine is not run-
If engine does not start, let engine come ning, turn Engine Control switch to Run/Idle Also in the Stick position, the arc drive (dig)
to a complete stop before attempting re- position and press Magnetic Shutdown circuit provides additional amperage during
start. switch. low voltage (short arc length conditions) to
Above 32 F (0 C): turn Engine Control prevent “sticking” electrodes.
10 Battery Voltmeter (Optional)
switch to Start while pressing Shutdown When switch is in Scratch Start TIG position,
switch. Release Engine Control switch when Use gauge to check battery voltage and moni-
the max OCV and arc drive (dig) circuits are
engine starts. Continue holding Shutdown tor the engine charging system. The meter
disabled and OCV changes when the control
switch until engine indicator lights go out. should read about 14 volts dc when the en-
is adjusted.
gine is running, and about 12 volts dc when
Below 32 F (0 C) using optional starting
aid switch: the engine is stopped. 16 Amperage Adjust Switch And Remote
11 Engine Temperature Gauge (Optional) Amperage Adjust Receptacle
Deutz F4L2011-powered units − Turn Engine Normal temperature is 212 - 239° F (100 - Connect optional remote control to RC13
Control switch to Run/Idle position. Push 115° C). If equipped with gauge option, engine (See Section 5-12). Use switch to select front
Starting Aid switch up for 60 seconds. While stops if temperature exceeds 270° F (132° C). panel or remote amperage control. For re-
still holding Starting Aid switch, press Mag- mote control, place switch in Remote position
netic Shutdown switch and turn Engine Con- 12 Engine Oil Pressure Gauge (Optional)
and connect remote control to Remote Am-
trol switch to Start. Release Engine Control Normal pressure is 30 − 60 psi (206 − 414 perage Adjust receptacle RC13 (see Sec-
switch and Starting Aid switch when engine kPa). If equipped with gauge option, engine tions 5-12 and 6-3).
starts. Continue holding Shutdown switch un- stops if pressure is below 20 psi (138 kPa).
til engine indicator lights go out. 17 Polarity Switch (Optional)
Weld Controls
Deutz F3L912-powered units − Press Mag- Do not switch under load.
netic Shutdown switch and turn Engine Con- Max OCV Control Circuit: This unit has
trol switch to Start. While cranking engine, a max OCV control circuit that resets Am- Use switch to change weld output. Select ei-
push Starting Aid switch up and release. Re- perage Adjust control R1 to maximum ther DC Electrode Positive (DCEP) or DC
lease Engine Control switch when engine when the arc breaks. When an arc is Electrode Negative (DCEN).
starts. Continue holding Shutdown switch un- struck, weld output control returns to the
til engine indicator lights go out. Weld Meters
R1 front panel or combination front panel/
To Stop: turn Engine Control switch to Off remote control setting. The Amperage 18 DC Voltmeter (Optional)
position. Adjust control adjusts amperage only
when welding and does not adjust open- Voltmeter displays voltage at the weld output
Engine Indicator Lights terminals, but not necessarily the welding arc
circuit voltage.
4 Battery Charging Light due to resistance of cable and connections.
Light goes on if engine alternator is not charg- The max OCV circuit is disabled when
ing battery. Engine continues to run. 19 DC Ammeter (Optional)
the Stick/TIG Selection switch is in
Stop engine and fix trouble if Battery Scratch Start TIG position (see item 15). Ammeter displays amperage output of the
Charging light goes on. unit.

6-3. Remote Amperage Control On CC Models (Optional)
1 Remote Amperage Adjust
1 Receptacle RC13
In Example:
Example: Combination Remote Amperage Control (Stick) Range = 125 to 320 A DC
Percentage Of Range = 50%
Max = About 223 A DC (50% of 125 to 320)
Max (223 A DC)
Min (87 A DC)
Set Switches Set Range Set Control Adjust Optional Remote Control
0774 / Ref. 154 862-A / Ref. 181 711-A / 802 311-A
6-4. Weld Control/Arc Condition Information Label

Set weld controls as shown to
achieve softer or stiffer arc condi-
tions for different applications.
212 944-A

Notes

SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS
7-1. Front Panel Controls For CC/CV Models (See Section 7-2)
5 6
4 7
14 15 18 19 10 11 12
3 1
13 16
17
202 706 / 802 311-D

7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)
Engine Starting Controls Engine Indicator Lights 14 Ampere Range Switch

1 Magnetic Shutdown Switch 4 Battery Charging Light Do not switch under load.
Use switch during start-up to bypass engine Light goes on if engine alternator is not charg-
shutdown system. System stops engine if oil ing battery. Engine continues to run. Use switch to select weld amperage range.
pressure is too low or engine temperature is Stop engine and fix trouble if Battery Use the lowest four ranges for Stick and TIG
too high. Charging light goes on. welding. Read the upper set of numbers at
2 Starting Aid Switch (Optional) 5 Engine Temperature Light each range for Stick welding and the lower set
Use switch to energize starting aid for cold at each range for TIG welding.
Light goes on and engine stops if engine oil
weather starting. temperature is above 266 ° F (130° C). Use the highest range for MIG welding and for
Deutz F4L2011-powered units use a glow Stop engine and fix trouble if Engine cutting and gouging (CAC-A).
plug starting aid. Push switch up for 60 sec- Temperature light goes on.
onds to operate the glow plug before cranking For most welding applications, use lowest
engine (see starting instructions following). 6 Engine Oil Pressure Light amperage range possible to help prevent arc
Light goes on and engine stops if oil pressure outages.
Deutz F3L912-powered units use an ether
starting aid system. Push switch up and re- is below 22 psi (150 kPa). Light goes on mo-
15 Voltage/Amperage Adjust Control
lease while cranking engine to release ether mentarily during start-up but goes out when
(see starting instructions following). engine reaches normal oil pressure. With Process/Contactor switch in any Stick or
Stop engine and fix trouble if Engine TIG setting, use control to adjust amperage
3 Engine Control Switch within range selected by Ampere Range
Oil Pressure light stays on after start-
Use switch to start engine, select engine up. switch. With Process/Contactor switch in any
speed (if unit has auto idle option), and stop MIG position, use control to adjust voltage.
7 Fuel Light
engine. With Voltage/Amperage Adjust Switch in Re-
Fuel light is not active on this model. mote position, control limits the remote am-
In Run position, engine runs at weld/power
speed. In Run/Idle position (optional), engine 8 Engine Hour Meter perage in TIG mode, but has no effect in Stick
runs at idle speed at no load and weld speed and MIG modes.
Engine Gauges
with load applied. Weld output would be about 223 A DC with
To Start:
To read gauges and engine indicator
controls set as shown (50% of 125 to 320 A).
lights with engine off, turn Engine Control
If engine does not start, let engine come switch to Run/Idle and press Magnetic The numbers around the control are for
to a complete stop before attempting re- Shutdown switch (see Section 11-1).
reference only and do not represent an
start. 9 Fuel Gauge actual percentage value.
Above 32 F (0 C): turn Engine Control Use gauge to check fuel level.
switch to Start while pressing Shutdown 16 Voltage/Amperage Adjust Switch And
switch. Release Engine Control switch when To check fuel level when engine is not run- Remote 14 Receptacle
engine starts. Continue holding Shutdown ning, turn Engine Control switch to Run/Idle
position and press Magnetic Shutdown Use switch to select front panel or remote
switch until engine indicator lights go out. voltage/amperage control. For remote con-
switch.
Below 32 F (0 C) using optional starting trol, place switch in Remote position and con-
aid switch: 10 Battery Voltmeter (Optional) nect remote control to Remote 14 receptacle
Deutz F4L2011-powered units − Turn Engine Use gauge to check battery voltage and moni- RC14 (see Sections 5-13 and 7-4).
Control switch to Run/Idle position. Push tor the engine charging system. The meter
Starting Aid switch up for 60 seconds. While should read about 14 volts dc when the en- 17 Polarity Switch (Optional)
still holding Starting Aid switch, press Mag- gine is running, and about 12 volts dc when Do not switch under load.
netic Shutdown switch and turn Engine Con- the engine is stopped.
trol switch to Start. Release Engine Control 11 Engine Temperature Gauge (Optional) Use switch to change weld output. Select ei-
switch and Starting Aid switch when engine ther DC Electrode Positive (DCEP) or DC
starts. Continue holding Shutdown switch un- Normal temperature is 212 - 239° F (100 - Electrode Negative (DCEN).
til engine indicator lights go out. 115° C). If equipped with gauge option, engine
stops if temperature exceeds 270° F (132° C). Weld Meters
Deutz F3L912-powered units − Press Mag- 12 Engine Oil Pressure Gauge (Optional) 18 DC Voltmeter (Optional)
netic Shutdown switch and turn Engine Con- Normal pressure is 30 − 60 psi (206 − 414
trol switch to Start. While cranking engine, kPa). If equipped with gauge option, engine Voltmeter displays voltage at the weld output
push Starting Aid switch up and release. Re- stops if pressure is below 20 psi (138 kPa). terminals, but not necessarily the welding arc
lease Engine Control switch when engine due to resistance of cable and connections.
starts. Continue holding Shutdown switch un- Weld Controls
til engine indicator lights go out. 13 Process/Contactor Switch 19 DC Ammeter (Optional)
To Stop: turn Engine Control switch to Off See Section 7-3 for Process/Contactor Ammeter displays amperage output of the
position. switch information. unit.

7-3. Process/Contactor Switch On CC/CV Models
1 Process/Contactor Switch
Weld output terminals are ener-
gized when Process/Contactor
switch is in an Electrode Hot posi-
tion and the engine is running.
1
DC voltage is still present at the
weld terminals when Process/
Contactor switch is in the Remote
− Stick position and the engine is
running.
Use switch to select weld process and
weld output on/off control (see table below
and Section 7-4).
Place switch in Remote positions to turn
weld output on and off with a device con-
nected to the remote 14 receptacle.
Place switch in Electrode Hot positions for
weld output to be on whenever the engine
is running.
Use Stick position for air carbon arc
(CAC-A) cutting and gouging.
When switch is in a Stick position, the arc
drive (dig) circuit provides additional am-
perage during low voltage (short arc
length conditions) to prevent “sticking”
electrodes.
The arc drive (dig) circuit is disabled when
switch is in MIG or TIG positions.
Place switch in Electrode Hot - Stick

position when using optional three-
phase generator (see Section 7-4).
The engine auto idle option does not

work in the Remote-TIG mode.
202 706
Process/Contactor Switch Settings
Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)
GTAW With HF Unit, Pulsing

Remote − TIG At Remote 14 Receptacle Not Active
Device, Or Remote Control
Remote − Stick Stick (SMAW) With Remote On/Off At Remote 14 Receptacle Active
Remote − MIG MIG (GMAW) At Remote 14 Receptacle Active
Electrode Hot − MIG MIG (GMAW) Electrode Hot Active
Stick (SMAW),
Electrode Hot − Stick Air Carbon Arc (CAC-A) Cutting Electrode Hot Active
And Gouging
Electrode Hot − Scratch

Scratch Start TIG (GTAW) Electrode Hot Active
Start TIG

7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)
1 Remote 14 Receptacle RC14
Example: Combination Remote Amperage Control (Stick) In Example:

Process = Stick (Using Remote On/Off)
Range = 125 to 320 A DC
Min = 125 A DC
Max = 320 A DC
Max (320 A DC)
Min (125 A DC)

Set V/A Set Remote
Set Range Control Not Adjust Optional Remote Control
Adjust Switch Process
Used In Remote
Stick Mode
Example: Combination Remote Amperage Control (TIG) In Example:

Process = TIG (Using Remote On/Off)
Range = 40 to 200 A DC
Percentage Of Range = 50%
Min = 40 A DC
Max = About 120 A DC (50% of 40 to 200)
Max (120 A DC)
Min (40 A DC)

Set V/A Set Remote
Set Range Set Control Adjust Optional Remote Control
Adjust Switch Process
0774 / Ref. 192 895-A / 802 311-A

SECTION 8 − OPERATING AUXILIARY EQUIPMENT
8-1. Generator Power Receptacles (Standard Models)

1 120 V 20 A AC GFCI
Receptacle GFCI1
2 240 V 30 A AC Twistlock
Receptacle RC1
Receptacles supply 60 Hz single-
phase power at weld/power speed.
If a ground fault is detected, GFCI
1 2
Reset button pops out and
receptacle does not work. Check
for faulty tools plugged in
3
receptacle. Press button to reset
GFCI1.
At least once a month, run en-

gine at weld/power speed and
press test button to verify GFCI
is working properly.
4 3 Circuit Breaker CB1
4 Circuit Breaker CB2
CB1 protects RC1 and the genera-
tor winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset breaker.
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset breaker.
If a circuit breaker continues to

open, contact Factory Autho-
rized Service Agent.
Generator power is not af-

fected by weld output.
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all re-
ceptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
191 624

8-2. Connecting To Optional Three-Phase Generator (CC/CV Standard Models Only)
Place Process/Contactor switch
in Electrode Hot - Stick position
when using three-phase genera-
tor (see Section 7-3).
Single-Phase Power Connection 1 2
Single-Phase Generator Power
1 120/240 V 50 A Receptacle
RC5
RC5 is connected to the optional
three-phase generator and supplies
60 Hz single-phase power at weld/
power speed. Maximum output from
RC5 is 12 kVA/kW. Power available
at RC5 is reduced when welding.
Circuit breaker CB7 protects single-
phase receptacle RC5 and the load
wires from overload. If CB7 opens, all
three-phase generator output stops
and the receptacle does not work.
Three-Phase Generator Power
Three-Phase Power Connection AC Single Three
Output Phase Phase Stop engine.
1 3
Power and weld outputs are
Volts 120/240 240
live at the same time. Discon-
Close panel opening
Amps 50 48 nect or insulate unused
if no connections are
KVA/KW 12 20 cables.
made to generator.
Frequency 60 Hz Have qualified person install ac-
Engine Speed 1850 RPM cording to circuit diagram and
Lead 42 connects to GROUND stud on Generator Power Guidelines
front of unit. (see Section 14).
Jumper 42 is connected to 90 at factory. Remove generator power panel
mounting screws. Tilt panel forward.
93
3 Lead 93
91 4 Lead 92
Remove plug
before inserting 5 Lead 91
leads. Reinstall 90 6 Lead 42 (Circuit Grounding
bushing.
Lead)
92 7 Lead 90 (Neutral)
Rear Of Panel 4
5 8 Isolated Neutral Terminal
91 92 93
3 9 Jumper Lead 42
6 10 Grounding Terminal
2 Jumper 42 is connected to lead 90 at
factory. Jumper 42 may be discon-
12 nected from neutral to meet applica-
7
ble electrical codes.
Lead 42 connects to front panel
10 Ground stud.
11 User-Supplied Leads
12 Circuit Breaker CB7 User
11 Terminals
Connect user-supplied leads to ter-
Close panel minals on CB7 and to the isolated
opening if no neutral terminal and grounding termi-
9 connections nal as necessary.
are made to
generator. Circuit breaker CB7 protects
240V
single-phase receptacle RC5
8 120V
and the load wires from overload.
1-Phase
If CB7 opens, all three-phase
120V
generator output stops and the
240V Tools Needed: receptacle does not work.
240V 3-Phase Reinstall generator power panel.
240V
Ref. 197 399 / 802 332-B

8-3. Optional Generator Power Receptacles (Standard Models)
1 120 V 20 A AC GFCI
Receptacle GFCI1
2 240 V 16 A AC European
European Receptacle Receptacle RC1
5 1 2 3 240 V 15 A AC Australian
Receptacle RC1
4 240 V 15 A AC South African
Receptacle RC1
6
Receptacles supply 60 Hz single-
phase power at weld/power speed.
If a ground fault is detected, the
GFCI Reset button pops out and
the receptacle does not work.
Check for faulty tools plugged in
receptacle. Press button to reset
GFCI1.
At least once a month, run en-

gine at weld/power speed and
press test button to verify GFCI
Australian Receptacle
is working properly.
1 3 5 Circuit Breaker CB2
5
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
6 work. Press button to reset breaker.
CB3 protects RC1 from overload. If
CB3 opens, RC1 does not work.
Press button to reset breaker.
If a circuit breaker continues to

open, contact Factory Autho-
rized Service Agent.
Generator power is not af-

fected by weld output.
South African Receptacle Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
5 1 4 RC1. Maximum output from all re-
ceptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
6 (240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
191 624

8-4. Generator Power Receptacles (CE Models)
4 1 2 5 3
Ref. 204 258
Generator power is not affected by weld ing from overload. If CB1 opens, RC1 and
RC2 do not work. Place switch in On position
Maximum output is 4 kVA/kW from RC1 and
2.2 kVA/kW from RC2 or RC3. Maximum
output.
to reset breaker. output from all receptacles is 4 kVA/kW.
1 130 V 32 A AC Receptacle RC1 Combined output of receptacles is limited to
2 220 Volt 16 A AC Receptacle RC2 CB2 protects RC2, and CB3 protects RC3 4 kVA/kW output of generator. If maximum
3 130 Volt 16 A AC Receptacle RC3 from overload. If a circuit breaker opens, the output is exceeded, auxiliary equipment will
receptacle does not work. Place switch in On stop or not run properly.
Receptacles supply 60 Hz single-phase position to reset breaker.
power at weld/power speed. EXAMPLE: If 20 A is drawn from RC1, only
8 A is available at each of the other
If a circuit breaker continues to open, receptacles.
5 Circuit Breakers CB2 And CB3 contact Factory Authorized Service (110 V x 20 A) + ( 110 V x 8 A) + (110 V x 8
CB1 protects RC1 and the generator wind- Agent. A) = 4 kVA/kW.

SECTION 9 − MAINTENANCE (DEUTZ F4L2011−POWERED UNITS)
Note The oil/filter maintenance intervals are different for the Deutz F4L2011 and F3L912 engines
(see maintenance schedules following).
Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
9-1. Routine Maintenance (Deutz F4L2011-Powered Units)
Stop engine before maintaining.
Recycle See Engine Manual and Maintenance Label for

engine important start-up, service, and storage informa-
fluids. tion. Service engine more frequently if used in se-
vere conditions.
* To be done by Factory Authorized Service Agent.
Every 8 h
FUEL Drain Water

Check Fluid
Wipe Up WATER From Fuel
Levels. See
Spills. System. See
Section 5-9.
Section 9-6.
Every 50 h
Clean And
Clean Air Filter.
Tighten Weld
See Section 9-3.
Terminals.
Every 100 h
Clean Clean And

Cooling Tighten
System. Battery
Connections.
Check air cleaner

hoses for cracks
and loose clamps.
Every 250 h
Replace Check Check And

1/2 in.
Unreadable (13 mm) Belt Clean Spark
Labels. Tension. Arrestor. See
Section 9-4.
Every 500 h
Repair Or
Replace
Cracked
Cables.

Every 1000 h
Change Oil Filter.

Change Oil. See See Section 9-6.
Section 9-6. Service more often
in dirty conditions.
Service Welding
Change Fuel Generator Brushes
Filters. See And Slip Rings.
Section 9-6. Service More Often
In Dirty Conditions.*
Drain Sludge
FUEL From Fuel Check
Tank. See Valve
SLUDGE Section 9-6. Clearance.*
Blow Out Or
Vacuum Inside.
OR During Heavy
Service,
Clean Monthly.
Every 3000 h
Clean/Set
Injectors.*
Notes

9-2. Maintenance Label

9-3. Servicing Air Cleaner (Deutz F4L2011-Powered Units)
Stop engine.
Do not run engine without air
cleaner or with dirty element. En-
1 2 3 4 gine damage caused by using a
damaged element is not covered
by the warranty.
The air cleaner primary element can

be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
Optional makes cleaning a risk. Consider the
risk of unwarrantable equipment
5
damage when determining whether
to clean or replace the primary ele-
ment.
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 1 Housing
2 in (51 mm)
from element. 2 Safety Element (Optional)
3 Primary Element
4 Dust Cap
5 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
Blow Inspect
(if present). Reinstall cap.
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B

9-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units)

1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3 Exhaust Pipe
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
3 of exhaust pipe with fireproof
material.
2 1 Stop engine and let cool.
Reinstall cleanout plug.
Tools Needed:
3/8 in
802 170-A / Ref. 202 705 / Ref. 802 311-A / Ref. 802 160-B
Notes

9-5. Adjusting Engine Speed (Deutz F4L2011-Powered Units)
Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine no
load speed with a tachometer or fre-
quency meter (see table for no load
speeds). If necessary, adjust speed
as follows:
Start engine and run until warm.
On CC Models, place Stick/TIG
switch in Stick position.
On CC/CV models, turn Process/
Contactor switch to Stick − Elec-
trode Hot position.
Standard Models:
1 Engine Speed Adjustment
1850 rpm Max.
Screw
(61.6 Hz)
1250 rpm 2 Locking Nut
(41.5 Hz) Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
Do not set engine speed higher
than specified.
Models With Automatic Idle
(Optional)
3 Throttle Rod
4 Locknut
Loosen locknuts. Place engine
Standard Models control switch in Run/Idle position.
Turn throttle rod until engine runs at
idle speed. Tighten locknuts.
5 Engine Speed Adjustment
Screw
2 6 Locknut
Place engine control switch in Run
position.
1
Loosen locknut. Turn screw until
engine runs at weld/power speed.
Tighten locknut.

than specified.
Stop engine.
Models With Automatic Idle (Optional) Close door.
4 3
6
Tools Needed:
3/8, 7/16 in
802 313-A

9-6. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units)
Tools Needed:
7/16, 11/16 in
1
7
Ref. 800 159-E / Ref. 802 170 / 802 313-A
Stop engine and let cool. maintenance label for oil/filter change in- See engine manual.
After servicing, start engine and formation. Close doors.
check for fuel leaks. Stop engine, To drain water from fuel system: To drain sludge from fuel tank:
tighten connections as necessary,
and wipe up spilled fuel. Open primary fuel filter petcock and drain Beware of fire. Do not smoke and
water into metal container. Close petcock keep sparks and flames away from
1 Oil Filter
when water-free fuel flows. drained fuel. Dispose of drained fuel
2 Oil Drain Valve And Hose in an environmentally-safe manner.
3 Oil Fill Cap To replace primary fuel filter:
Do not leave unit unattended while
4 Primary Fuel Filter (Fuel/Water Sepa- Turn filter counterclockwise. Remove filter. draining fuel tank.
rator) Properly lift unit and secure in a level
Apply thin coat of fuel to gasket on new filter.
5 Petcock Fill filter with fuel. Install filter and turn clock- position. Use adequate blocks or
6 Secondary Fuel Filter wise. Bleed air from fuel system according stands to support unit while drain-
to engine manual. ing fuel tank.
7 Fuel Tank Sludge Drain Valve
Inspect fuel line, and replace if cracked or Attach 1/2 ID hose to drain valve. Put metal
To change oil and filter: container under drain, and use screwdriver
worn.
Route oil drain hose and valve through hole to open sludge drain valve. Close valve
in base. See engine manual and engine To replace secondary fuel filter: when sludge has drained. Remove hose.

9-7. Overload Protection (Deutz F4L2011-Powered Units)
Stop engine.
When a circuit breaker or fuse opens,

it usually indicates a more serious
problem exists. Contact Factory Au-
thorized Service Agent.
1 Fuse F1
2 Fuse F2
F1 and F2 protect the stator exciter wind-
ing from overload. If F1 opens, weld and
generator power is low or stops entirely.
If F2 opens, weld output is low or stops
entirely. 4 kVA/kW generator power is still
available.
3 Circuit Breaker CB4 (Not Shown)
2 1 (CC/CV Models Only)
(CC/CV Models Only)
7 (Optional − Not Shown)
CB4 protects the welding arc drive (dig)
circuit. If CB4 opens, electrode may stick
to the workpiece more frequently during
low voltage (short arc length) conditions.
CB4 automatically resets when the fault is
corrected.
CB5 protects the 24 volt ac output to re-
mote receptacle RC14, and 24 volt output
to field current regulator board PC1 (CC/
CV models only). If CB5 opens, weld out-
4 5 put and 24 volt output to RC14 stops. On
units with optional three-phase genera-
tor, generator power output at receptacle
RC5 also stops if CB5 opens.
mote receptacle RC14 (CC/CV models
only). If CB6 opens, 115 volt output to
RC14 stops.
CB10 protects the engine battery circuit.
If CB10 opens, the engine will not crank.
CB10 automatically resets when the fault
is corrected.
CB11 protects the engine wiring harness.
On CC models, if CB11 opens the max
OCV circuit does not work and open cir-
cuit voltage is variable at all times (see
max OCV note under Weld Controls in
Section 6-2). If CB11 opens on CC/CV
models, weld output stops (generator
power is still available).
CB12 protects the field flashing circuit. If
CB12 opens, the generator may not ex-
cite at start-up and weld and generator
power output may not be available.
CB13 protects the engine shutdown cir-
cuit. If CB13 opens, the engine cranks but
does not start.
CB14 protects the throttle solenoid on
units with the auto idle option. If CB14
opens, the engine will not run at idle
speed. CB14 automatically resets when
the fault is corrected.
802 170-D / Ref. 802 311

SECTION 10 − MAINTENANCE (DEUTZ F3L912−POWERED UNITS)
Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
10-1. Routine Maintenance (Deutz F3L912-Powered Units)
Stop engine before maintaining.
Recycle See Engine Manual and Maintenance Label for

engine important start-up, service, and storage informa-
fluids. tion. Service engine more frequently if used in se-
vere conditions.
* To be done by Factory Authorized Service Agent.
Every 8 h
FUEL Drain Water

Check Fluid
Wipe Up WATER From Fuel
Levels. See
Spills. System. See
Section 5-9.
Section 10-7.
Every 50 h
Clean And
Clean Air Filter.
Tighten Weld
See Section
Terminals.
10-3.
Every 100 h
Clean Clean And

Cooling Tighten
System. Battery
Connections.
Check air cleaner

hoses for cracks
and loose clamps.
Every 250 h
Replace 1/2 in. Check

Unreadable (13 mm) Belt
Labels. Tension.
Check And
Clean Spark
Arrestor. See
Section 10-4.

Every 500 h
Change Oil Filter.

Change Oil. See See Section 10-7.
Section 10-7. Service more often
in dirty conditions.
Repair Or
Check Replace
Valve Cracked
Clearance.* Cables.
Every 1000 h
Service Welding
Change Fuel Generator Brushes
Filters. See And Slip Rings.
Section 10-7. Service More Often
In Dirty Conditions.*
Drain Sludge Blow Out Or

FUEL From Fuel Vacuum Inside.
Tank. See OR During Heavy
SLUDGE Section Service,
10-7. Clean Monthly.
Every 3000 h
Clean/Set
Injectors.*
Notes

10-2. Maintenance Label

10-3. Servicing Air Cleaner (Deutz F3L912-Powered Units)
Stop engine.
Do not run engine without air
cleaner or with dirty element. En-
1 2 3 4 gine damage caused by using a
damaged element is not covered
by the warranty.
The air cleaner primary element can

be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
Optional makes cleaning a risk. Consider the
risk of unwarrantable equipment
5
damage when determining whether
to clean or replace the primary ele-
ment.
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 1 Housing
2 in (51 mm)
from element. 2 Safety Element (Optional)
3 Primary Element
4 Dust Cap
5 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
Blow Inspect
(if present). Reinstall cap.
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B

10-4. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units)

1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3 Exhaust Pipe
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
3 of exhaust pipe with fireproof
material.
2 1 Stop engine and let cool.
Reinstall cleanout plug.
Tools Needed:
3/8 in
802 170-A / Ref. 202 705 / Ref. 802 311-A / Ref. 802 160-B
Notes

10-5. Adjusting Engine Speed (Deutz F3L912-Powered Units)
Stop engine.
Engine speeds have been factory
set and should not require adjust-
ment. After tuning engine, check
Engine Speed engine speeds with a tachometer.
(No Load) RPM See table for proper no load speed.
If necessary, adjust speed as fol-
lows:
Weld/Power 1850 1 Speed Adjustment Screw
2 Locknut
Loosen nut. Start engine.
Turn screw until engine runs at
weld/power speed. Tighten locknut.

than specified.
Stop engine.
Close side door.
2
1
Tools Needed:
9/16, 7/8 in
802 398 / 134 730-C
10-6. Servicing Optional Ether Starting Aid (Deutz F3L912-Powered Units)

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 Ether Cylinder
1
2 Valve
3 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 Section 5-8.
33 oz 15 oz
(935 g) (425 g)
Full Empty
ether2 7/96 − ST-153 382-A / Ref. 202 705 / S-0692

10-7. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units)
Tools Needed:
7/16, 11/16 in
2
1
Ref. 800 159-E / Ref. 802 170 / 802 398
Stop engine and let cool. maintenance label for oil/filter change in- See engine manual.
formation.
After servicing, start engine and Close doors.
check for fuel leaks. Stop engine, To drain water from fuel system:
tighten connections as necessary, To drain sludge from fuel tank:
and wipe up spilled fuel. Open primary fuel filter petcock and drain Beware of fire. Do not smoke and
1 Oil Filter water into metal container. Close petcock keep sparks and flames away from
when water-free fuel flows. drained fuel. Dispose of drained fuel
2 Oil Drain Valve And Hose
To replace primary fuel filter: in an environmentally-safe manner.
3 Oil Fill Cap
Do not leave unit unattended while
4 Primary Fuel Filter (Fuel/Water Sepa- Turn filter counterclockwise. Remove filter. draining fuel tank.
rator)
Apply thin coat of fuel to gasket on new filter. Properly lift unit and secure in a level
5 Petcock Fill filter with fuel. Install filter and turn clock- position. Use adequate blocks or
6 Secondary Fuel Filter wise. Bleed air from fuel system according stands to support unit while drain-
to engine manual. ing fuel tank.
7 Fuel Tank Sludge Drain Valve
Inspect fuel line, and replace if cracked or Attach 1/2 ID hose to drain valve. Put metal
To change oil and filter:
worn. container under drain, and use screwdriver
Route oil drain hose and valve through hole to open sludge drain valve. Close valve
in base. See engine manual and engine To replace secondary fuel filter: when sludge has drained. Remove hose.

10-8. Overload Protection (Deutz F3L912-Powered Units)
Stop engine.
When a circuit breaker or fuse

opens, it usually indicates a more se-
rious problem exists. Contact Facto-
ry Authorized Service Agent.
1 Fuse F1
2 Fuse F2
F1 and F2 protect the stator exciter wind-
ing from overload. If F1 opens, weld and
generator power is low or stops entirely.
If F2 opens, weld output is low or stops
entirely. 4 kVA/kW generator power is still
available.
2 1 4 Circuit Breaker CB5
(CC/CV Models Only)
(CC/CV Models Only)
7
(Not Shown)
CB4 protects the welding arc drive (dig)
circuit. If CB4 opens, electrode may stick
to the workpiece more frequently during
low voltage (short arc length) conditions.
is corrected.
mote receptacle RC14, and 24 volt output
4 5 to field current regulator board PC1 (CC/
CV models only). If CB5 opens, weld out-
put and 24 volt output to RC14 stops. On
units with optional three-phase genera-
tor, power output at receptacle RC5 also
stops if CB5 opens.
mote receptacle RC14 (CC/CV models
only). If CB6 opens, 115 volt output to
RC14 stops.
CB10 protects the engine battery circuit.
If CB10 opens, the engine will not crank.
is corrected.
CB11 protects the engine wiring harness.
On CC models, if CB11 opens the max
OCV circuit does not work and open cir-
cuit voltage is variable at all times (see
max OCV note under Weld Controls in
Section 6-2). If CB11 opens on CC/CV
models, weld output stops (generator
power is still available).
CB12 protects the field flashing circuit. If
CB12 opens, the generator may not ex-
cite at start-up and weld and generator
power output may not be available.
CB13 protects the engine shutdown cir-
cuit. If CB13 opens, the engine cranks but
does not start.
CB14 protects the engine fuel solenoid.
If CB14 opens, the engine will not start.
is corrected.
Ref. 802 313-A

SECTION 11 − TROUBLESHOOTING
11-1. Diagnosing Causes Of Engine Fault Shutdowns

Use the front panel engine lights to
help determine the cause of an au-
tomatic engine shutdown.
Pre-Start Diagnostic Checks Correct the cause of the shut-

down before operating the
welding generator.
This unit does not have a bat-

tery charging fault shutdown.
The engine continues to run if
the Battery Charging Light
goes on.
Turn Engine Control Switch To Run/Idle Normal Condition:

Position While Pressing Magnetic Oil Pressure Light On;
Shutdown Switch. Battery Charging And Temperature Lights Off.
If Oil Pressure Light Is Off, See Factory Authorized Service Agent.
If Battery Charging Light Is On, Have Factory Authorized Service
Agent Check Alternator.
If Temperature Light Is On, Correct Cause Of Overheating
(See Engine Manual).
If Engine Is Okay, See Factory Authorized Service Agent.
If Fault Continues, See Factory Authorized Service Agent.
Diagnostic Checks While Running
20s
Start Engine (With No Load Applied). Continue Pressing Shutdown Switch Normal Condition:
Until Engine Lights Go Off. Engine Lights Go Off As Engine Reaches
Normal Operating Condition.
Lights That Stay On After 20 Sec. Indicate Fault
Condition.
Stop Engine And Correct Fault (See Above) If Fault
Continues, See Factory Authorized Service Agent.
Ref. 202 705

11-2. Troubleshooting Tables
A. Welding − CC Models
Trouble Remedy
No weld output; generator power output Check position of Ampere Range switch.
okay at ac receptacles.
Check position of optional polarity switch.
Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
control to Remote Amperage Adjust receptacle RC13 (see Sections 5-12 and 6-1).
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-12).
Check fuse F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent check inte-
grated rectifier SR2 and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (see Section 9-7
or 10-8).
Erratic weld output. Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Have Factory Authorized Service Agent check brushes and slip rings.
High weld output. Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).
Have Factory Authorized Service Agent check OCV control circuit.
Low weld output. Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).
Check fuses F1 and F2, and replace if open (see Section 9-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-7
frequently during low voltage (short arc or 10-8). Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and
length) conditions. SR5.
Low open-circuit voltage. Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).
Maximum weld output only in each Have Factory Authorized Service Agent check control relay CR7.
ampere range (with Stick/TIG Selection
switch in Stick position).
No remote fine amperage control. Place Amperage Adjust switch in correct position.
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-12).
Repair or replace remote control device.
Reset circuit breaker CB11 (see Section 9-7). Have Factory Authorized Service Agent check control relay
CR7.
Have Factory Authorized Service Agent check OCV control circuit.
Have Factory Authorized Service Agent check control relay CR7.

B. Welding − CC/CV Models
Trouble Remedy
No weld output; generator power output Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and
okay at ac receptacles. connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-13 and 7-1).
Check position of Ampere Range switch.
Check position of optional polarity switch.
Reset circuit breaker CB11 (see Section 9-7 or 10-8).
Reset circuit breaker CB5 (see Section 9-7 or 10-8). Check for faulty remote device connected to
RC14.
Check and secure connections to Remote 14 receptacle RC14 (see Section 5-13).
Have Factory Authorized Service Agent check connector board PC6 and connections.
Check fuse F2, and replace if open (see Section 9-7 or 10-8). Have Factory Authorized Service Agent
check brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Check fuses F1 and F2, and replace if open (see Section 9-7 or 10-8). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Erratic weld output. Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
High weld output. Check position of Ampere Range switch and Voltage/Amperage Adjust control.
Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).
Have Factory Authorized Service Agent check field current regulator board PC1.
Voltage/Amperage control does not Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere
work when welding in Stick mode. Range switch in highest range.
Low weld output. Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).
Agent check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-7
frequently during low voltage (short arc or 10-8). Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and
length) conditions. SR5.
Low open-circuit voltage. Check engine weld/power speed, and adjust if necessary.
No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position.
control.
Constant speed wire feeder does not Reset circuit breaker CB5 or CB6 (see Section 9-7 or 10-8).
work.
Repair or replace wire feeder.
Low CV weld output. Set Ampere Range switch to highest range.
Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.

C. Standard Generator Power
Trouble Remedy
No generator power output at ac recep- Reset receptacle circuit breakers.

tacles; weld output okay.
No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
Agent check integrated rectifier SR1, capacitor C9, and the rotor.
Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 (CC models) or field
current regulator board PC1 (CC/CV models) (see Section 9-7 or 10-8).
High output at generator power ac re- Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).
ceptacles.
Have Factory Authorized Service Agent adjust generator power field current resistor R3.
Low output at generator power ac recep- Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).
tacles.
Check fuse F1, and replace if open (see Section 9-7 or 10-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, resistor R3, and capacitor C9.
D. Optional Three-Phase Generator Power (CC/CV Models Only)
Trouble Remedy
No or low output at optional three- Place Process/Contactor switch in Electrode Hot - Stick position (see Section 7-3).
phase generator/receptacle RC5.
Reset circuit breaker CB7 (see Section 8-2).
Reset circuit breaker CB5 (see Section 9-7 or 10-8).
Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).
Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
PC1.
High output at optional three-phase Check engine weld/power speed, and adjust if necessary (see Section 9-5 or 10-5).
generator/receptacle RC5.
Erratic output at optional three-phase Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
generator/receptacle RC5. PC1.
E. Engine
Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-7
or 10-8). Have Factory Authorized Service Agent check engine wiring harness and components.
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check Engine Control switch S1.

Trouble Remedy
Engine cranks but does not start. Press Magnetic Shutdown switch MS1 when starting engine.
Check fuel level.
Reset circuit breaker CB13 (see Section 9-7 or 10-8). Have Factory Authorized Service Agent check en-
gine wiring harness and components.
Check battery and replace if necessary. Check engine charging system according to engine manual.
On Deutz F3L912-powered units, allow circuit breaker CB14 to reset. Have Factory Authorized Service
Agent check fuel solenoid FS1 (see Section 10-8).
Have Factory Authorized Service Agent check control relay CR2, and fuel solenoid FS1.
Air in fuel system. See engine manual.
Engine starts, but stops when Magnetic When starting engine, continue holding Magnetic Shutdown switch until after engine indicator lights go
Shutdown switch is released. out.
Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Sections 5-9 and 11-1).
Engine hard to start in cold weather. Use optional starting aid switch (see Section 6-1 or 7-1).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 9-2 or 10-2).
Engine suddenly stops. Check fuel level.
Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Sections 5-9 and 11-1).
See engine manual.
Engine slowly stopped and cannot be Check fuel level.

restarted.
Check engine air and fuel filters (see Sections 9-3 and 9-6, or Sections 10-3 and 10-7).
See engine manual.
Battery discharges between uses. Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine idles, but does not come up to Have Factory Authorized Service Agent check idle module PC7.
weld speed (models with idle option
only).
Check for obstructed throttle solenoid.
Engine does not run at idle speed CC models: place Stick/TIG Selection switch in Stick position.
(models with idle option only). CC/CV models: place Process/Contactor switch in any position but Remote-TIG.
Check for obstructed throttle solenoid.
Allow circuit breaker CB14 to reset. Have Factory Authorized Service Agent check throttle solenoid TS1
and linkage (see Section 9-7).
Have Factory Authorized Service Agent check idle module PC7, control relays CR3 and CR6, and current
transformer CT1.
Engine uses oil during run-in period; Dry engine (see Section 13).
wetstacking occurs.

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)

SECTION 12 − ELECTRICAL DIAGRAMS
Figure 12-1. Circuit Diagram For CC Welding Generator (Non-CE Deutz F4L2011-Powered Units)

215 302-A

Figure 12-2. Circuit Diagram For CC Welding Generator (CE Compliant Deutz F4L2011-Powered Units)

216 530-A

Figure 12-3. Circuit Diagram For CC/CV Welding Generator (Non-CE Deutz F4L2011-Powered Units)

215 303-A

Figure 12-4. Circuit Diagram For CC/CV Welding Generator (CE Compliant
Deutz F4L2011-Powered Units)

216 531-A

Figure 12-5. Circuit Diagram For CC Welding Generator (Deutz F3L912-Powered Units)

215 298-A

Figure 12-6. Circuit Diagram For CC/CV Welding Generator (Deutz F3L912-Powered Units)

215 299-A

SECTION 13 − RUN-IN PROCEDURE
13-1. Wetstacking
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
1 Welding Generator
2 Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
Do not idle engine longer than

necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generator is kept loaded during
1 run-in.
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.

13-2. Run-In Procedure Using Load Bank
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Keep exhaust and pipe away
4
from flammables.
2 procedure at less than 20
1 exceed duty cycle or equip-
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe correct
polarity.
Start engine and run for several
minutes.
3 Set load bank switches and then
adjust generator A/V control so load
equals rated voltage and current of
generator (see nameplate, rating
label, or the specifications section
in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
Check oil level frequently dur-

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.
Repeat procedure if wetstacking is
present.
S-0683

13-3. Run-In Procedure Using Resistance Grid
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Keep exhaust and pipe away
6
from flammables.
2 procedure at less than 20
exceed duty cycle or equip-
1 Resistance Grid
Use grid sized for generator rated
output.
1 Turn Off grid.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connec-
tors (polarity is not important).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
3 5 Start engine and run for several
minutes.
Set grid switches and then adjust
generator A/V control so load
equals rated voltage and current of
the generator (see nameplate, rat-
4 ing label, or the specifications sec-
tion in this manual).
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
+ loaded properly.
Check oil level frequently dur-

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.
Repeat procedure if wetstacking is
present.
S-0684

SECTION 14 − GENERATOR POWER GUIDELINES
NOTE The views in this section are intended to be representative of all engine-driven
welding generators. Your unit may differ from those shown.
14-1. 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
Do not use 2-prong plug un-
less equipment is double in-
sulated.
Be sure equipment
OR
has this symbol
and/or wording.
gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577
14-2. Grounding Generator To Truck Or Trailer Frame

Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
1 Equipment Grounding
Terminal (On Front Panel)
2 Grounding Cable (Not
Supplied)
1 3 Metal Vehicle Frame
GND/PE 2 Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
If unit does not have GFCI re-
3 ceptacles, use GFCI-pro-
tected extension cord.
Electrically bond generator

frame to vehicle frame by
metal-to-metal contact.
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

14-3. Grounding When Supplying Building Systems
1 Equipment Grounding
Terminal
1 2
2 Grounding Cable
GND/PE
Use #10 AWG or larger insulated
copper wire.
3 Ground Device
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Use ground device as stated

in electrical codes.
2 3
ST-800 576-B
14-4. How Much Power Does Equipment Require?

1 Resistive Load
3 A light bulb is a resistive load and
VOLTS 115 requires a constant amount of power.
2 AMPS 4.5
1 Hz 60 2 Non-Resistive Load
Equipment with a motor is a non-re-
sistive load and requires approxi-
mately six times more power while
starting the motor than when running
(see Section 14-8).
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
requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from 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

14-5. Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Split Phase 1/8 HP 800 300
1/6 HP 1225 500
1/4 HP 1600 600
1/3 HP 2100 700
1/2 HP 3175 875
Capacitor Start-Induction Run 1/3 HP 2020 720
1/2 HP 3075 975
3/4 HP 4500 1400
1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000
5 HP 23300 6000
7-1/2 HP 35000 8000
10 HP 46700 10700
Fan Duty 1/8 HP 1000 400
1/6 HP 1400 550
1/4 HP 1850 650
1/3 HP 2400 800
1/2 HP 3500 1100
14-6. Approximate Power Requirements For Farm/Home Equipment

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

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

14-8. Power Required To Start Motor
4 1 Motor Start Code
AC MOTOR 2 2 Running Amperage
1 VOLTS 230 AMPS 2.5
3 Motor HP
3 CODE M Hz 60
4 Motor Voltage
HP 1/4 PHASE 1
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running 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
Single-Phase Induction Motor Starting Requirements motor’s running amperage.
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
= STARTING AMPERAGE
VOLTS
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
14-9. 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
2 supply.
Ref. ST-800 396-A / S-0625

14-10. Typical Connections To Supply Standby Power
Properly install and ground this equipment according to

its Owner’s Manual and national, state, and local codes.
1 2 3 4
Fused
Utility Welding
Disconnect
Electrical Transfer Switch Generator
Switch
Service Output
(If Required)
Essential
Loads
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
es. restored. Turn off or unplug all equipment connected to
generator before starting or stopping engine.
Properly install and ground this Install correct switch (customer-supplied). When starting or stopping, the engine has
equipment according to its Owner’s Switch rating must be same as or greater low speed which causes low voltage and
Manual and national, state, and local than the branch overcurrent protection. frequency.
codes.
3 Fused Disconnect Switch
5 Essential Loads
Customer-supplied equipment is re- Install correct switch (customer-supplied) if
quired if generator will supply standby required by electrical code. Generator output may not meet the electrical
power during emergencies or power out- requirements of the premises. If generator
4 Welding Generator Output
ages. does not produce enough output to meet all
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. tion 14-4).
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

14-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
Load (Watts) 4 6 8 10 12 14
(Amperes)
5 600 350 (106) 225 (68) 137 (42) 100 (30)
7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)
10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)
15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)
20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)
25 3000 175 (53) 112 (34) 62 (19) 37 (11)
30 3600 150 (46) 87 (26) 50 (15) 37 (11)
35 4200 125 (38) 75 (23) 50 (15)
40 4800 112 (34) 62 (19) 37 (11)
45 5400 100 (30) 62 (19)
50 6000 87 (26) 50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
Load (Watts) 4 6 8 10 12 14
(Amperes)
5 1200 700 (213) 450 (137) 225 (84) 200 (61)
7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)
10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)
15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)
20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)
25 6000 350 (107) 225 (69) 125 (38) 75 (23)
30 7000 300 (91) 175 (53) 100 (31) 75 (23)
35 8400 250 (76) 150 (46) 100 (31)
40 9600 225 (69) 125 (38) 75 (23)
45 10,800 200 (61) 125 (38)
50 12,000 175 (53) 100 (31)
*Conductor size is based on maximum 2% voltage drop

SECTION 15 − PARTS LIST
Hardware is common and not
available unless listed.
A Deutz F4L2011 engine-pow-

ered unit is shown below. See
insert for parts specific to a
15
Deutz F3L912-powered unit.
Parts not related to the engines
are the same in both units.
14
3 16
2
17
13
1
12
18
4 11
5 6 19
9
10
8
7
109(CV)
108(CV)
12 21
102 (Fig. 14-7) 20
103 101 94
22
92
127
100 (FIG. 15-2 OR 15-3)
97 (CC ONLY)
107 98
99 (CC ONLY) 95
93
105 104
96
106 (FIG. 15-4 OR 15-5)
CC CC Models Only
CV CC/CV Models Only
Figure 15-1. Main Assembly


A Deutz F4L2011 en- Deutz F3L912 Engine
gine-powered unit is
shown below. See in-
sert for parts specific to 29
a Deutz F3L912-pow-
121 124
ered unit. Parts not re- 54
lated to the engines are
the same in both units. 126
120 32 112
119 122
110
55
116 56
125
115
123 62
117
67
58
118 63
64 59
113 65
60
111 61 47
69
114
16 70
17 46
71
29 34 (Fig. 15-6) 72 45
44
48
25 28
30
26 27 43 50
24
51
52
23
42
49
32
33 41
40
53
31 39
38
54
37
54
36
35 76
55 75
56 74
62 73
63
34 (Fig. 15-6) 57
64 58
67 65 59 77
66 60
86 82
83 87 61 78
84 88 68
85
69
70
89
71
72 81
80 79
90
91
802 331-F
92

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 15-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 189 824 .. PANEL, gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 1 . . . . . . . . . . . . ♦199 294 .. PANEL, gen LH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 191 623 .. LABEL, warning all panels must be in place while running . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . 176 106 .. LABEL, warning moving parts (Wordless Label) . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . +189 828 .. PANEL, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . ♦+199 301 .. PANEL, engine side ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦212 570 .. Baffle, engine side (CE Rated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . . 189 395 .. REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . ♦201 520 .. REACTOR, ac environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . 1T . . . . 038 621 .. BLOCK, term 30A 4 pole frict term str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 038 620 .. LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . 081 499 .. BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 206 352 .. BRACE, front to center upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . SR4, SR5 . 035 704 .. RECTIFIER, integ bridge 40. amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . CB4 . . . 045 061 .. CIRCUIT BREAKER, auto reset 24vdc 7 amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . 201 697 .. PAN, reactor and rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . . 201 613 .. TRANSFORMER w/bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . ♦205 636 .. TRANSFORMER w/bracket (environmental coating) . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 173 352 .. EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 3ft
. . . 13 . . . . . . . . . . . . . 189 708 .. FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 191 307 .. COVER, plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 191 829 .. HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 189 763 .. BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 189 764 .. AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192 938 .. FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *♦192 939 .. FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 189 464 .. SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 173 909 .. HOSE, sae .312 id x .560 od x 24.000 (order by ft) . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . 201 658 .. UPRIGHT, center assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . +200 999 .. BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . ♦+203 382 .. BASE e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 196 220 .. BRACKET, hold down fuel tank rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 192 362 .. BRACKET, mtg nyl 1/2 conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . +201 934 .. COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . ♦+202 640 .. COVER, top ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 189 052 .. GROMMET, plastic neck filler fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 190 198 .. CAP, tank screw-on 3.500 in w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 192 041 .. LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 176 103 .. LABEL, use diesel fuel only (Wordless Label) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . 108 487 .. LABEL, warning falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . . 176 104 .. LABEL, warning falling equipment (Wordless Label) . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . . . . 176 230 .. LABEL, warning hot exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 105 734 .. PIPE, muffler extension elbow 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 201 592 .. PIPE, exhaust (CE Rated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 201 851 .. COVER, radiator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 191 354 .. SUPPORT, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 202 633 .. SUPPORT, cover e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 010 875 .. CLAMP, muffler 2.000 dia u pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . 200 730 .. MANIFOLD, exhaust muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . Figure 15-6 .. GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . 013 367 .. LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . . 176 106 .. LABEL, warning moving parts (Deutz F4L2011) (Wordless Label) . . . . . . 2
. . . 36 . . . . . . . . . . . . . 191 577 .. GUARD, starter (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . 191 809 .. BRACKET, mtg engine LH (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . 190 951 .. EDGE TRIM, styel tl750-b2 x 1/16 black w/clips 1.625 . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . 191 817 .. BAFFLE, air (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Item Dia. Part
Figure 15-1. Main Assembly (Continued)
. . . 40 . . . . . . . . . . . . . 213 877 . . ENGINE, Deutz dsl elec F4L2011 (consisting of) . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *067 265 . . . . FILTER, oil (engine) (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192 744 . . . . FILTER, fuel spin-on (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *066 217 . . . . FILTER, fuel secondary (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *195 745 . . . . SWITCH, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *195 746 . . . . SENDER, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . ♦174 064 . . IDLE, solenoid assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . ♦175 937 . . BRACKET, support solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . *067 266 . . BELT, blower (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . 201 714 . . BOX, air intake (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . 201 748 . . UPRIGHT, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . ♦202 638 . . UPRIGHT, rear ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . 190 206 . . CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 46 . . . . . . . . . . . . . 190 207 . . CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . 203 430 . . BRACKET, battery holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . 190 897 . . BATTERY, stor 12V 650crk 110rsv gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . 201 006 . . BOLT, j stl .312−18 x 8.500 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 50 . . . . . . . . . . . . +201 183 . . COVER, battery access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . 202 639 . . COVER, battery access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . 176 108 . . LABEL, warning battery explosion can blind (Wordless Label) . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . 147 923 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . 176 106 . . LABEL, warning moving parts (Wordless Label) . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . +215 252 . . GUARD, belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . 147 923 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . 3
. . . 55 . . . . . . . . . . . . . 199 849 . . SCREW, 625-11 x 4.00hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 56 . . . . . . . . . . . . . 071 731 . . WASHER, flat .656 ID x 2.250 OD x .187T stl pld . . . . . . . . . . . . . . . . . . . . 4
. . . 57 . . . . . . . . . . . . . 191 812 . . BRACKET, mtg engine RH (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 59 . . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 60 . . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 . . . . . . . . . . . . . . . . . . 4
. . . 61 . . . . . . . . . . . . . 135 205 . . NUT, 625-11 .94hex .76H stl pld elastic stop nut . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 199 507 . . HOSE, oil drain assy 20 in (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . 165 271 . . . . VALVE, oil drain 3/8-18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . 176 529 . . . . FITTING, hose brs barbed fem 1/2tbg x 3/8NPT . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 113 854 . . . . HOSE, SAE .500 ID x .780 OD xc oil (order by ft) . . . . . . . . . . . . . . . . . . 2ft
. . . 65 . . . . . . . . . . . . . 176 528 . . FITTING, hose brs barbed elbow fem 1/2 tbg x 1/2 NPT . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . 173 336 . . FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . . . . . . . . . . . WASHER, oil drain (available through engine manufacturer) . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . 191 816 . . BRACKET, mtg fuel filter/solenoid (Deutz F4L2011 engine) . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . 192 750 . . BASE, fuel filter w/adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 192 741 . . BLOCK, spacer mtg filter base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . 145 282 . . FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT . . . . . . . . . . . . . . . . 2
. . . 71 . . . . . . . . . . . . . 107 816 . . HOSE, SAE .250 ID x .500 OD xc oil (order by ft) . . . . . . . . . . . . . . . . . . . . 3ft
. . . . . . . . . . . . . . . . . . . 134 835 . . HOSE, SAE .312 ID X .560 OD X 31.000 (order by ft) . . . . . . . . . . . . . . 4.5ft
. . . 72 . . . . . . . . . . . . . *192 744 . . FILTER, fuel spin-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . 190 992 . . KEEPER, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . 190 076 . . CHANNEL, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . ♦202 635 . . CHANNEL, stiffener engine access e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . 199 592 . . LATCH, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . 200 444 . . LABEL, diesel engine maintenance Deutz (Wordless Label) . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . +200 989 . . DOOR, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . +210 736 . . DOOR, engine access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . 189 975 . . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 79 . . . . . . . . . . . . . 208 141 . . STOP, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 80 . . . . . . . . . . . . . 189 826 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Item Dia. Part
. . . 80 . . . . . . . . . . . . . 199 298 . . PANEL, rocker ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 81 . . . . . . . . . . . . . 189 827 . . PANEL, gen RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 81 . . . . . . . . . . . . . 199 300 . . PANEL, gen RH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . 191 626 . . BUMPER, door engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 83 . . . . . . . . . . . . . 189 245 . . TANK, fuel 23gal (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 084 173 . . . . CLAMP, hose .460 − .545clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 85 . . . . . . . . . . . . . 189 912 . . . . FITTING, stl barbed elbow w/.047 in orf zinc pld . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . 189 909 . . . . FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . 189 913 . . . . FITTING, stl barbed elbow zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . 190 142 . . . . SENDER, fuel gauge 9.7500 deep tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . 189 910 . . . . FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . 189 908 . . . . VALVE, drain fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . . 181 572 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . . 191 446 . . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . . . 6ft
. . . 93 . . . . . . . . . . . . . 191 897 . . BRACKET, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 94 . . . . . . . . . . . . . 191 512 . . BRACKET, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . 190 250 . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 95 . . . . . . . . . . . . . 200 864 . . LABEL, warning do not weld on base (Wordless Label) . . . . . . . . . . . . . . . 2
. . . 96 . . . . . . . . . . . . . 190 179 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . R4 . . . CC191 292 . . RESISTOR, WW fxd 375W 50 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . R2 . . . . 189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . R3 . . . CC189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . Figure 15-2, Figure 15-3 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . 189 731 . . FIREWALL, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . Figure 15-7 . . MAIN RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . 191 448 . . TOP, cover front upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . ♦199 305 . . TOP, cover front upright ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . . . . . . . +201 750 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . . . . . . ♦+202 637 . . UPRIGHT, front ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . 134 792 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . 176 105 . . LABEL, warning general precautionary (Wordless Label) . . . . . . . . . . . . . . 1
. . 106 . . . . . Figure 15-4, Figure 15-5 PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . . . . . . . . . ♦202130 . . XFMR, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . CV193 453 . . BRACKET, mtg box fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . PC1 . . CV189 143 . . MODULE, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 190 058 . . NUT, .250-20 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . 049 525 . . NUT, 312-18 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . 202 031 . . KIT, label (includes safety and informational labels) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 062 . . KIT, label (includes safety and informational labels) (Wordless Labels) . . 1
. . 110 . . . . . . . . . . . . 199 063 . . ENGINE, Deutz dsl elec F3L912 d0392−166/00 . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . . . . . . . . . . . *064 677 . . FILTER, oil (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 112 . . . . . . . . . . . . *066 271 . . BELT, blower (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 113 . . . . . . . . . . . . *195 745 . . SWITCH, pressure oil 1.5 bar nc cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 114 . . . . . . . . . . . . *195 746 . . SENDER, coolant temp & 130 degee C switch . . . . . . . . . . . . . . . . . . . . . . 1
. . 115 . . . . . . . . . . . . 194 135 . . BACKPLATE, Deutz F3L912 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 116 . . . . . . . . . . . . 194 572 . . SUPPORT, front engine (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . 1
. . 117 . . . FS1 . . . 141 346 . . SHUTDOWN KIT, engine (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . 1
. . 118 . . . . . . . . . . . . . 118 452 . . FTG, adapter oil drain (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . 1
. . 119 . . . . . . . . . . . . 193 313 . . MANIFOLD, exhaust muffler (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . 1
. . 120 . . . . . . . . . . . . 194 496 . . BAFFLE, lower air outlet (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . 1
. . 121 . . . . . . . . . . . . 194 497 . . BAFFLE, upper air outlet (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . 1
. . 122 . . . . . . . . . . . . 194 500 . . BAFFLE, air intake (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 123 . . . . . . . . . . . . 194 485 . . HOSE, air cleaner (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 124 . . . . . . . . . . . +201 714 . . BOX, air intake (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Item Dia. Part
..125 . . . . . . . . . . . . 195 560 . . GUARD, starter hole (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . 1

..126 . . . . . . . . . . . . 194 467 . . WASHER, flat 6.25idx11.50odx.062t buna n . . . . . . . . . . . . . . . . . . . . . . . . . 1
..127 . . . . . . . . . . . . 212 944 . . LABEL, cc stick overlap weld ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 202 031 or Label Kit 201 062 (Wordless Labels).
* Recommended Spare Parts.
C CC models only.
C
V CC/CV models only.

C
♦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.
14 4
18
6
22
3
17
7 8
2
21
1 20
23
15
11
10
19
16 5
13
12 802 551-E
Figure 15-2. Control Box Assembly − CC Models

Item Dia. Part
Figure 15-2. Control Box Assembly − CC Models (Figure 15-1 Item 100)
... 1 . . . F1, F2 . . *085 874 .. FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 2 ............. 046 432 .. HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 ............. 201 077 .. CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 ............. 201 078 .. CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 ............. 201 079 .. COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . C12 . . . 191 944 .. CAPACITOR, polyp met film 10. uf 250 vac 10% . . . . . . . . . . . . . . . . . . . . 1

Item Dia. Part
Figure 15-2. Control Box Assembly − CC Models (Continued)
. . . . . . . . . . . . . . . . . . . 201 681 . . HARNESS, control box, weld control (consisting of) . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . CR7 . . . 188 636 . . . . RELAY, OCV control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . R8 . . . . 214 863 . . . . RESISTOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . SR1, SR2 . 035 704 . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . CR5 . . . 090 104 . . . . RELAY, encl 12VDC SPST 30A/15VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH, tgl spdt 15a 125vac on−none−on spd term chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 15-4) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . . 011 622 . . . . SWITCH, tgl 3pdt 15a 125vac on−none−on spd term
. . . . . . . . . . RC4 . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . . . . . 1
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 177 859 . . . . CONN, body 5 terminal (to engine control switch S1) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 150 316 . . . . CONN, rect univ 039 6p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . . . 6
. . . 11 CB11, 12, 13 139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . 190 260 . . HARNESS, unit weld control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . 158 465 . . . . CONN, rect univ 084 12p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187 654 . . . . SEAL, wire univ 12p/s 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114 063 . . . . CONN, rect univ 084 4p/s 1row plug cable lkg . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 192 309 . . . . CLIP, snap in .630 bundle .250 hole .248 thk . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . C9 . . . . . 087 110 . . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . R6 . . . . 141 424 . . RESISTOR, ww fxd 30 w 25 ohm faston te . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . PC7 . . ♦195 706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CR4 . . ♦113 247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . . 1
. . . 17 . . . . CR6 . . ♦090104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
. . . 18 . . CR2, CR3 . 090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 206 024 . . HARNESS, engine control (Deutz F4L2011 engine) (consisting of) . . . . 1
. . . 19 . . . D1/C1 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . CB10 . . . 190 374 . . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 173 916 . . . . HOUSING, contact 10-pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . CB14 . . ♦205 927 . . . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . CR1 . . . 214 876 . . . . RELAY, encl 6vdc spst 35a/14vdc 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 205 931 . . HARNESS, engine control (Deutz F3L912 engine) (consisting of) . . . . . 1
. . . 19 . . . D1/C1 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . CB14 . . . 205 927 . . . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . CR8 . . ♦155 309 . . CONTACTOR, solenoid 12VDC cont 400A inrush . . . . . . . . . . . . . . . . . . . . 1
♦Optional
*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.

4
16
19
3
15
17
11
2
20
1
18
21
12 5
13
10
14
7
6
8
9 802 360
Figure 15-3. Control Box Assembly − CC/CV Models
Item Dia. Part

Figure 15-3. Control Box Assembly − CC/CV Models (Figure 15-1 Item 100)
. . . 1 . . . F1, F2 . . *085 874 . . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 2 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . 201 077 . . CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 201 078 . . CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 201 079 . . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 134 201 . . STAND-OFF, support pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 7 . . . . PC9 . . . 192 224 . . CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . C9 . . . . . 087 110 . . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 495 . . HARNESS, control box, cv weld control (consisting of) . . . . . . . . . . . . . . . 1
. . . 10 . . . . SR1 . . . 035 704 . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . CR5 . . . 090 104 . . . . RELAY, encl 12VDC SPST 30A/15VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . . 1
. . . 12 CB11, 12, 13 139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . 193 324 . . . . SWITCH, rotary 6 position gold contacts
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH,tgl spdt 15a 125vac on−none−on spd term chr
. . . . . . . . . . . . . . . . . . . 177 859 . . . . CONN, body 5 terminal (to engine control switch S1) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 193 183 . . . . CONN, rect cinch 18 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Item Dia. Part
Figure 15-3. Control Box Assembly − CC/CV Models (Continued)
. . . . . . . . . . . . . . . . . . . 196 602 . . . . PLUG, cavity 18,30 position cinch connector . . . . . . . . . . . . . . . . . . . . . . 4

. . . . . . . . . . . . . . . . . . . 196 603 . . . . SEAL, switch 6 position rotary .250 shaft . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 141 450 . . . . CONN, rect metrmate 10skt 1row plug cable lkg . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . PC7 . . ♦195 706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CR4 . . ♦113 247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CR6 . . ♦090104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
. . . 16 . . CR2, CR3 . 090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 2
. . . 17 . . . . . R8 . . . . 214 863 . . . . RESISTOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 173 916 . . . . HOUSING, contact 10-pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . CB14 . . ♦205 927 . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . R8 . . . . 214 863 . . . . RESISTOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 185 655 . . . . SEAL, wire univ 15P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . CB14 . . . 205 927 . . . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . CR8 . . ♦155 309 . . CONTACTOR, solenoid 12VDC cont 400A inrush . . . . . . . . . . . . . . . . . . . . 1
♦Optional
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)

4
Hardware is common and
not available unless listed.
5
2
1
6
7
8
9
10
41 11
40
39
12
13
14
15
16
36 35
34 17
37
33 32 18
38
31
30
29
19
20
22
21
23
28
27
26 25 24 802 266-D
Figure 15-4. Panel, Front w/Components − CC Models
Item Dia. Part

Figure 15-4. Panel, Front w/Components − CC Models (Figure 15-1 Item 106)
. . . 1 . . . . . . . . . . . . . 202 705 . . PLATE SCREENED, ident control rating; when ordering this item,
.............................. the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 ........................ NAMEPLATE, screened (order by model and serial number) . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 201 580 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . ♦202 642 . . PANEL, engine/weld control ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . 189 382 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 202 223 . . BUS BAR, idealized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Item Dia. Part
Figure 15-4. Panel, Front w/Components − CC Models (Continued)
. . . . . . . . . . . . . . . . . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . 188 635 . . RHEOSTAT, WW 300W 34 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 7 . . . . . S6 . . . . . 011 622 . . SWITCH, tgl DPDT 15A 125VAC (included in control box harness,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Figure 15-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see Figure 15-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . RC13 . . . 032 897 . . RECEPTACLE, twlk grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 045 . . COVER, receptacle twistlock (for RC13 (European Receptacle) . . . . . . . 1
. . . 10 . . . . . S1 . . . . 176 606 . . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S2 . . . ♦021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . MS1 . . . 189 698 . . SWITCH, magnetic manual reset low current . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB1 . . . 201 083 . . CIRCUIT BREAKER, man reset 2P 20 A, 250VAC (European Receptacle)1
. . . 13 . . . . CB1 . . ♦202 683 . . CIRCUIT BREAKER, man reset 2p 40a 240vac screw−90 (CE Rated) . . 1
. . . . . . . . . . . . . . . . . . ♦197 527 . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB2, CB3 ♦201 083 . . CIRCUIT BREAKER, man reset 2p 20a 250vac . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 201 109 . . HARNESS, generator power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB2 . . . 093 996 . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . 3
. . . 15 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . 1
. . . 16 . . . . RC1 . . . 147 632 . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦201 053 . . HARNESS, generator power (European Receptacle) (consisting of) . . . . 1
. . . 14 . . . . CB2 . . ♦093 996 . . . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . 1
. . . 14 . . . . CB3 . . ♦139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . GFCI1 . ♦151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦213 577 . . HARNESS, generator power (CE Rated) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦189 549 . . BLOCK, term assy standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦038 620 . . LINK, jumper term block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . RC1 . . ♦176 355 . . RECEPTACLE, str 2p3w 16a 220v flange mtg (European Receptacle) . . 1
. . . 16 . . . . RC1 . . ♦173 556 . . RECEPTACLE, str 2p3w 32a 130v flange mtg (CE Rated) . . . . . . . . . . . . 1
. . . . . . . . . . RC2 . . ♦176 355 . . RECEPTACLE, str 2p3w 16a 220v flange mtg (CE Rated) . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 190 861 . . LABEL, warning electric shock and moving parts . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 200 910 . . LABEL, warning, electric shock and moving parts (Wordless Label) . . . . 1
. . . 18 . . . . . . . . . . . . +201 106 . . PANEL, gen pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . ♦+202 641 . . PANEL, gen pwr ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . ♦+201 052 . . PANEL, gen pwr (European Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . ♦+204 258 . . PANEL, gen pwr (110/220 volt receptacles) (CE Rated) . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . ♦+210 750 . . PANEL, gen pwr ss (European Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 083 030 . . STUD, brs .250−20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . 601 836 . . NUT, 250−20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 21 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . ♦199 303 . . PANEL, mtg terminal pwr output ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 193 260 . . COVER, receptacle 2.250 dia lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 193 258 . . COVER, receptacle GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Item Dia. Part
Figure 15-4. Panel, Front w/Components − CC Models (Continued)
. . . 32 . . . . . . . . . . . . . 190 323 .. BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 33 . . . . . . . . . . . . . 193 143 .. BOOT, magnetic shutdown switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 021 385 .. BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 119 014 .. LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . PL1 . . . 191 241 .. LED, red 12V 4 ind lights panel mtg round . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . FUEL . . . 192 265 .. GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . HM . . . . . 118 058 .. METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . 189 161 .. HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 010 647 .. PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . 019 602 .. KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 024 103 .. BLANK, snap−in nyl .750 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

not available unless listed.
5
6
2 7
8
1 9
10
58
57 11
56 12
13
55 14
15
16
54 17
18
19
20
34 21
51
52 50 22
49 31
53 48 30
33 23
47
24
46
32 26
29
44
28 25
45 27
35
36
43
37
42
41 40 39 38
802 332-F
Figure 15-5. Panel, Front w/Components − CC/CV Models
Item Dia. Part

Figure 15-5. Panel, Front w/Components − CC/CV Models (Figure 15-1 Item 106)
. . . 1 . . . . . . . . . . . . . 202 706 . . PLATE SCREENED, ident control; when ordering this item,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, screened (order by model and serial number) . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 201 580 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . ♦202 642 . . PANEL, engine/weld control ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . 189 382 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦202 223 . . BUS BAR, idealized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . . 193 118 . . POT, cp flat 1t 2w 1k ohm linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Item Dia. Part
Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued)
. . . 6 . . . . . S6 . . . . 193 234 . . SWITCH, rotary 6 position gold contacts (included in control box harness,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Figure 15-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see Figure 15-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . PC6 . . . 192 995 . . CIRCUIT CARD ASSY, connector/receptacle . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CB5 . . . 139 266 . . CIRCUIT BREAKER, man reset 1p 15a 250vac frict . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S1 . . . . 176 606 . . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . S2 . . . . 021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . MS1 . . . 189 698 . . SWITCH, magnetic manual reset low current . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB1 . . . 201 083 . . CIRCUIT BREAKER, man reset 2P 20 A, 250VAC . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB1 . . ♦202 683 . . CIRCUIT BREAKER, man reset 2p 40a 240vac screw−90 . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦197 527 . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB2, CB3 ♦201 083 . . CIRCUIT BREAKER, man reset 2p 20a 250vac . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 201 109 . . HARNESS, generator power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC1 . . . 147 632 . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦201 053 . . HARNESS, generator power (European Receptacle) (consisting of) . . . . 1
. . . . . . . . . . CB3 . . . 139 266 . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦213 577 . . HARNESS, generator power (CE Rated) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦189 549 . . BLOCK, term assy standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦038 620 . . LINK, jumper term block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC1 . . . 176 355 . . RECEPTACLE, str 2p3w 16a 220v flange mtg (European Receptacle) . . 1
. . . 17 . . . . RC1 . . ♦173 556 . . RECEPTACLE, str 2p3w 32a 130v flange mtg (CE Rated) . . . . . . . . . . . . 1
. . . 18 . . . . RC5 . . ♦182 954 . . RCPT, str 3P4W 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . ♦025 248 . . STAND-OFF, insul .250-20 x 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . ♦604 102 . . CONNECTOR, clamp cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . ♦197 527 . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦197 363 . . TERMINAL, ring tng screw clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . CB7 . . ♦196 780 . . CIRCUIT BREAKER, man reset 3p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . +201 106 . . PANEL, generator power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . ♦+202 641 . . PANEL, gen pwr ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . ♦+201 052 . . PANEL, gen pwr (European Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . ♦+204 258 . . PANEL, gen pwr (110/220 volt receptacles) (CE Rated) . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . +♦201 107 . . PANEL, generator power (full kVA option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . ♦196 781 . . BOOT, circuit breaker 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . ♦197 508 . . PLUG, protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . ♦077 440 . . BUSHING, conduit 1 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 601 836 . . NUT, 250−20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 39 . . . . . . . . . . . . ♦197 291 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 083 030 . . STUD, brs .250−20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CT2 . . ♦197 433 . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 190 861 . . LABEL, warning electric shock and moving parts . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 200 910 . . LABEL, warning, electric shock and moving parts (Wordless Label) . . . . 1
. . . 31 . . . . . . . . . . . . ♦197 399 . . LABEL, warning 3 ph generator power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 193 260 . . COVER, receptacle 2.250 dia lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . 193 258 . . COVER, receptacle GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Item Dia. Part
Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued)
. . . 37 . . PC4, PC5 . 189 744 . . CIRCUIT CARD ASSEMBLY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 38 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 39 . . . . . . . . . . . . . 134 201 . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 40 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 41 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 42 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . 193 143 . . BOOT, magnetic shutdown switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 119 014 . . LEVER, switch black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 50 . . . . . . . . . . . . . 170 391 . . CONN, circ ms protective cap size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . PL1 . . . 191 241 . . LED, red 12V 4 ind lights panel mtg round . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . FUEL . . . 192 265 . . GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . HM . . . . . 118 058 . . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . 097 922 . . KNOB, pointer .875 dia x .250 ID w/set screws plstc . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . 097 924 . . KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . CB6 . . . 083 432 . . CIRCUIT BREAKER, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 193 158 . . HARNESS, unit weld control − CV (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114 063 . . . . CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . 193 184 . . . . CONNECTOR, rect cinch 30 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . 147 992 . . . . CONNECTOR, rect univ 039 10p/s 2 row plug cable . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . 158 465 . . . . CONNECTOR, rect univ 084 12p/s 3 row plug cable . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 088 731 . . . . BUSHING, snap-in nyl .375 ID x .500 mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 135 873 . . . . CLIP, conduit convoluted 1/2 in mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 187 654 . . . . SEAL, wire univ 12p/s 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 024 103 . . BLANK, snap-in nyl .750 mtg hole blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 120 304 . . BLANK, snap−in nyl .250 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
♦Optional

not available unless listed. 16
17
18
11 15
12
10
14
9
13
19
8 20
21
7
6
5
3 22
4 23
24
2 26 25
1 27
28
29
30
31
32
33
34 802 404-C
Figure 15-6. Generator

Item Dia. Part
Figure 15-6. Generator (Figure 15-1 Item 34)
. . . 1 . . . . . . . . . . . . . 132 053 . . SCREW, 375-16 x 1.50hexhd pln gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . 2 . . . . . . . . . . . . . 183 387 . . WASHER, conical spring .406 ID x .875 OD pltd . . . . . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 195 911 . . ENDBELL, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 143 220 . . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 201 099 . . STATOR, exciter/gen pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . ♦213 448 . . STATOR, exciter/gen pwr (CE Rated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . +208 287 . . STATOR, weld assembly complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . +♦209 220 . . STATOR, weld assembly complete (full kVA option) . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . 176 106 . . LABEL, warning moving parts (Wordless Label) . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . 190 197 . . GUARD, generator wire mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 172 674 . . SPRING, ext .240 OD x .041 wire x 3.500pld . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . 039 207 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . ROTOR . . . 212997 . . ROTOR, Generator Segmented Assy (Includes) . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 210 446 . . . . ROTOR, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . 024 617 . . . . . . RING, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 053 390 . . . . . . BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HUB, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 210 447 . . . . FAN, Rotor Assy Generator (Segmented) (includes) . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 210 332 . . . . . . PLATE, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 206 242 . . . . . . FAN, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . 049 026 . . . . . . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . 10
. . . 18 . . . . . . . . . . . . . 083 883 . . . . . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . 10
. . . 19 . . . . . . . . . . . . . 080 389 . . . . . . SCREW, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . 8
. . . 20 . . . . . . . . . . . . . 083 883 . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . 4

Item Dia. Part
Figure 15-6. Generator (Continued)
. . . 21 . . . . . . . . . . . . . 049 026 . . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 22 . . . . . . . . . . . . . 191 579 . . COVER, starter hole Perkins/Continental . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 083 883 . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . 6
. . . 24 . . . . . . . . . . . . . 172 555 . . SCREW, M10-1.5 x 50hexhd pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 25 . . . . . . . . . . . . . 602 159 . . SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw . . . . . . . . . . . . . 6
. . . 26 . . . . . . . . . . . . . 601 961 . . SCREW, .312-18 x 2.25hexhd pln gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 27 . . . . . . . . . . . . . . 602 211 . . WASHER, lock .318 ID x 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 28 . . . . . . . . . . . . . 139 341 . . WASHER, exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 29 . . . . . . . . . . . . . *190 823 . . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 30 . . . . . . . . . . . . . 208 469 . . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 31 . . . . . . . . . . . . . 189 142 . . BRUSHHOLDER ASSEMBLY, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 602 242 . . WASHER, flat .375IDx0.875odx.083t stl pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 602 211 . . WASHER, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . 2
. . . 34 . . . . . . . . . . . . . 604 534 . . SCREW, .312−18x1.25 hex hd−pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 190 259 . . HARNESS, brush (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . 168 071 . . . . CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187 651 . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Notes

4
not available unless listed. 3
1
5
802 279-A
Figure 15-7. Main Rectifier Assembly
Item Dia. Part

Figure 15-7. Main Rectifier Assembly (Figure 15-1 Item 102)
. . . . . . . . . . SR3 . . . 201 747 . . RECTIFIER (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . SR3 . . ♦203 381 . . RECTIFIER, environmental (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . . 188 137 . . . . CONNECTION BOARD, rectifier AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 188 517 . . . . BUS BAR, connection board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . . . . . . . . . . . . 188 135 . . . . ENCLOSURE, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 134 201 . . . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . PC3 . . . 201 449 . . . . CIRCUIT CARD ASSEMBLY, protection . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 188 136 . . . . INSULATOR, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 7 . . . . . . . . . . . . . 188 493 . . . . HEAT SINK, rectifier al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . D3, D5, D7 208 334 . . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 208 335 . . . . DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Effective January 1, 2003
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
Call LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold
* APT & SAF Model Plasma Cutting Torches
for your local after the effective date of this limited warranty is free of defects * Remote Controls
in material and workmanship at the time it is shipped by Miller. * Accessory Kits
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or * Canvas Covers
Your distributor also gives replace any warranted parts or components that fail due to
you ... Miller’s True Blue Limited Warranty shall not apply to:
such defects in material or workmanship. Miller must be
Service notified in writing within thirty (30) days of such defect or 1. Consumable components; such as contact tips,
failure, at which time Miller will provide instructions on the cutting nozzles, contactors, brushes, slip rings,
You always get the fast,
warranty claim procedures to be followed. relays or parts that fail due to normal wear.
reliable response you (Exception: brushes, slip rings, and relays are
need. Most replacement Miller shall honor warranty claims on warranted equipment
covered on Bobcat, Trailblazer, and Legend models.)
parts can be in your listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that 2. Items furnished by Miller, but manufactured by others,
hands in 24 hours. the equipment was delivered to the original retail purchaser, or such as engines or trade accessories. These items are
Support one year after the equipment is sent to a North American covered by the manufacturer’s warranty, if any.
Need fast answers to the distributor or eighteen months after the equipment is sent to an
International distributor. 3. Equipment that has been modified by any party other
tough welding questions? than Miller, or equipment that has been improperly
Contact your distributor. 1. 5 Years Parts — 3 Years Labor installed, improperly operated or misused based upon
The expertise of the * Original main power rectifiers industry standards, or equipment which has not had
distributor and Miller is reasonable and necessary maintenance, or equipment
* Inverters (input and output rectifiers only) which has been used for operation outside of the
there to help you, every
2. 3 Years — Parts and Labor specifications for the equipment.
step of the way.
* Transformer/Rectifier Power Sources MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Plasma Arc Cutting Power Sources PERSONS TRAINED AND EXPERIENCED IN THE USE
* Semi-Automatic and Automatic Wire Feeders AND MAINTENANCE OF WELDING EQUIPMENT.
* Inverter Power Supplies In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
* Maxstar 150 appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
3. 1 Year — Parts and Labor Unless Specified replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
* Motor Driven Guns (w/exception of Spoolmate transportation costs of any kind will be allowed.
Spoolguns)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Process Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Positioners and Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* RFCS Foot Controls PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources ANY OTHER LEGAL THEORY.
* Water Coolant Systems ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
* Flowgauge and Flowmeter Regulators (No Labor)
REPRESENTATION AS TO PERFORMANCE, AND ANY
* HF Units REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Grids OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
* Maxstar 85, 140 OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Spot Welders OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Load Banks PURPOSE, WITH RESPECT TO ANY AND ALL
* Racks EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
* Running Gear/Trailers DISCLAIMED BY MILLER.
* Plasma Cutting Torches (except APT & SAF Some states in the U.S.A. do not allow limitations of how long
Models) an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
* Field Options limitation or exclusion may not apply to you. This warranty
(NOTE: Field options are covered under True provides specific legal rights, and other rights may be
Blue for the remaining warranty period of the available, but may vary from state to state.
product they are installed in, or for a minimum of
one year — whichever is greater.) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
5. 90 Days — Parts Warranty provides specific legal rights, and other rights may
* MIG Guns/TIG Torches be available, but may vary from province to province.
miller_warr 8/03

Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters −
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
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  2003 Miller Electric Mfg. Co. 1/03

Big Blue 502D

Uploaded by

Document Informationclick to expand document information

Copyright:

Available Formats

Big Blue 502D

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Big Blue 502D

Uploaded by

Copyright:

Available Formats

OM-495 192 774AR

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Air Carbon Arc (CAC-A)

Engine Driven Welding Generator

Big Blue 402D, 502D, 602D

And Non-CE Models

Visit our website at

Miller Electric manufactures a full line

More user manuals on ManualsBase.com

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

More user manuals on ManualsBase.com

SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

More user manuals on ManualsBase.com

Manufacturer’s Name: Miller Electric Mfg. Co.

European Contact: Mr. Danilo Fedolfi, Managing Director

More user manuals on ManualsBase.com

Manufacturer’s Name: Miller Electric Mfg. Co.

Sound Level Information

European Contact: Mr. Danilo Fedolfi, Managing Director

More user manuals on ManualsBase.com

1-1. Symbol Usage

Marks a special safety message.

1-2. Arc Welding Hazards

More user manuals on ManualsBase.com

Watch for fire, and keep a fire extinguisher nearby.

1-3. Engine Hazards

BATTERY EXPLOSION can BLIND. MOVING PARTS can cause injury.

OM-495 Page 2 Return To Table Of Contents

More user manuals on ManualsBase.com

1-4. Compressed Air Hazards

TRAPPED AIR PRESSURE AND WHIPPING

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

FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING.

OVERHEATING can damage motors. STATIC (ESD) can damage PC boards.

FLYING SPARKS can cause injury.

Return To Table Of Contents OM-495 Page 3

More user manuals on ManualsBase.com

1-6. California Proposition 65 Warnings

1-7. Principal Safety Standards

1-8. EMF Information

OM-495 Page 4 Return To Table Of Contents

More user manuals on ManualsBase.com

2-1. Signification des symboles

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

Return To Table Of Contents OM-495 Page 5

2-3. Dangers existant en relation avec le moteur

LES ACCUMULATIONS DE GAZ ris- L’ACIDE DE LA BATTERIE peut pro-

OM-495 Page 6 Return To Table Of Contents

2-4. Dangers liés à l’air comprimé

L’AIR COMPRIMÉ peut provoquer DES PIECES CHAUDES peuvent provo-

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

Return To Table Of Contents OM-495 Page 7

2-6. Principales normes de sécurité

2-7. Information sur les champs électromagnétiques

OM-495 Page 8 Return To Table Of Contents

3-1. Warning Label Definitions (For Wordless Labels)