OM-4420 212 049K

October 2004

Processes
Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding
TIG (GTAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

Description

Engine Driven Welding Generator

Big Blue Turbo



Visit our website at

www.MillerWelds.com
 From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 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. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Sound Level Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-4. Stick And MIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-5. DC TIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-6. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-7. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-8. Generator AC Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-9. Manufacturing Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-3. Installing Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-6. Using The Optional Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-7. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-10. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-1. Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-2. Description Of Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-4. Using Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-1. 120 Volt And 240 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-2. Optional Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 8 − ENGINE/GENERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8-1. Routine Engine/Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8-2. Engine Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
 TABLE OF CONTENTS

8-4. Inspecting/Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8-6. Servicing Engine Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-7. Engine/Generator Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 11 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SECTION 13 − SELECTING AND PREPARING
TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
13-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
13-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding . . . . . . . . . . . . . . . . . . . . . . . . 55
13-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SECTION 14 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
14-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
14-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
14-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SECTION 15 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
 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.
OM-4420 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-4420 Page 2
 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.

OM-4420 Page 3
 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.

OM-4420 Page 4
 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.

OM-4420 Page 5
  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.

OM-4420 Page 6
  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.
OM-4420 Page 7
 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.

OM-4420 Page 8
 SECTION 3 − DEFINITIONS

3-1. Symbols And Definitions

Fast (Run, Weld/

Stop Engine Slow (Idle) Start Engine
Power)

Check engine belt Check Air Cleaner Starting Aid Engine

Battery (Engine) Hourmeter (HM) Temperature Circuit Breaker

Do Not Switch Read Operator’s Certified/Trained

Engine Oil
Under Load Manual Mechanic

Check Injectors/ Check Valve Engine Coolant

Fuel
Pump Clearance Temperature

Positive Negative Wire Feed Welding Arc

A Amperes
V Volts Panel/Local Remote

Direct Current Alternating Gas Tungsten Arc

Output
(DC) Current (AC) Welding (TIG)

Stick (SMAW) Constant Current MIG (GMAW) Constant Voltage

Welding (CC) Welding (CV)

3
Air Carbon Arc Protective Earth
Three Phase
1 Single Phase
Cutting (CAC-A) (Ground)

DC Electrode DC Electrode Electrode

Work Connection
Positive Negative Connection

On Off
h Hours
s Seconds

Time

OM-4420 Page 9
 SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications

Maximum
Weld Rated Engine
Welding Open-Circuit Generator Power Fuel Tank
Output Welding Engine Oil
Mode Voltage Rating Capacity
Range Output Capacity
(Nominal)

600 A,
44 Volts
CC/DC 20 − 750 A DC, 95
100% Duty Standard DEUTZ
Cycle Single-Phase, 11 qt
q 25 gal
g
4 kVA/kW,
kVA/kW 34/17 A A, Deutz BF4M2011 (10.4
(10 4 L) (95 L)
600 A, 120/240 V AC, Oil-Cooled,
36 Volts 50/60 Hz Four-Cylinder,
CV/DC 14 − 40 V DC, 56 Turbo-Charged
100% Duty 64 HP Diesel Engine
Cycle

4-2. Sound Level Table

Weld/Power Speed
Idle Speed (1235 rpm) 40 Volts DC At 500 Amps 44 Volts DC At 600 Amps
(1850 rpm)

94.6 Lwa sound power 100.6 Lwa sound power 103.0 Lwa sound power 104.5 Lwa sound power
69.7 dBa at 23 ft (7 m) 75.7dBa at 23 ft (7 m) 78.1 dBa at 23 ft (7 m) 79.6 dBa at 23 ft (7 m)
74.5 dBA 3.3 ft (1 m) 78.8 dBA 3.3 ft (1 m) from 86.0 dBA 3.3 ft (1 m) from 91.8 dBA 3.3 ft (1 m) from
from front panel front panel front panel front panel

4-3. Dimensions, Weights, And Operating Angles

Dimensions
54-1/2 in (1384 mm)
Height G
(to top of muffler)

28-1/2 in (724 mm)

(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
p unit where it could
ti
tip.
Depth 69-1/2 in (1765 mm)
A 69-1/2 in (1765 mm)
B* 55-7/8 in (1419 mm) A
C* 46-3/8 in (1178) B C
D* 11 in (279 mm)
E 27-1/2 in (699 mm)
F 1 in (25 mm) 30°
H
G 29-1/2 in (749 mm) 30°
20°
9/16 in (14 mm) Dia. D
H
4 Holes Front Panel End 20°
* With mounting brackets in center
position. Dimensions vary with loca- F
tion of mounting brackets. E
Weight

No Fuel: 1780 lb (807 kg) 802 161-A

803 452
w/Fuel: 1955 lb (997 kg)

OM-4420 Page 10
4-4. Stick And MIG Volt-Ampere Curves
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
A. DC Stick Mode other settings fall between the
curves shown.
100
Ranges
300 − Max
185 − 525
80 125 − 400
85 − 250
55 − 125
DC VOLTS

60

40

20

0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES

B. MIG Mode

100

80
DC VOLTS

60 MAX

40

20 MIN

0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES

208 135 / 203 415

OM-4420 Page 11
4-5. DC TIG Volt-Ampere Curves
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.

100
Ranges
60−450
80 40−330
30−220
20−110
DC VOLTS

60

40

20

0
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700
DC AMPERES

208 136

4-6. Fuel Consumption

The curve shows typical fuel use
under weld or generator power
loads.

3.00
2.75
2.50
2.25
2.00
US Gal./Hr.

1.75
1.50
1.25
1.00
0.75
0.50
IDLE
0.25
0.00
0 50 100 150 200 250 300 350 400 450 500 550 600
DC WELD AMPERES AT 100% DUTY CYCLE

Ref. 208 211

OM-4420 Page 12
4-7. Duty Cycle And Overheating
100% Duty Cycle At 600 Amperes Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.

Exceeding duty cycle can
damage unit and void
warranty.

Continuous Welding

1000
800
600
500
400
WELD AMPERES

300
250
200

150

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

212 060-C

4-8. Generator AC 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

100 200
AC VOLTS

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

OM-4420 Page 13
4-9. Manufacturing Rating Label

OM-4420 Page 14
 SECTION 5 − INSTALLATION
5-1. Installing Welding Generator

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 5-2 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 6/04 − Ref. 800 652 / Ref. 800 477-A / 803 274

OM-4420 Page 15
5-2. 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.
Using Mounting Brackets Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at
2 the four mounting brackets.

Welding Unit In Place

Bolting Unit In Place
3
2

Tools Needed:
9/16 in
install3 6/04 803 274 / 190 250-A / 803 231

OM-4420 Page 16
5-3. Installing Optional Spark Arrestor Muffler

Stop engine and let cool.
1 Spark Arrestor Muffler
2 Double-Flanged Elbow
3 Nut
4 Flat Washer
5 Mount
6 Bracket
7 Screw
8 Single-Flanged Elbow
2 9 Rain Cap
10 Clamp
Loosely assemble components as
10 1 shown.

9  Mount the muffler with the clean-

out plug to the outside.
After assembly, final-tighten all
clamps and hardware.

 Be sure to tighten rain cap

mounting screw.

6
8

5
4

Tools Needed:
7/16, 1/2 in 803 453

OM-4420 Page 17
5-4. 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

OM-4420 Page 18
5-5. 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

5-6. Using The Optional Battery Disconnect Switch

Stop engine.
1 Battery Disconnect Switch
1 OFF The battery disconnect switch dis-
connects battery voltage from the
circuit. When the switch is turned
Off, the front panel controls do not
work.
To run unit, turn switch to On posi-
ON tion. To prevent unit from running,
turn switch to Off position.
The switch may be locked using a
customer-supplied padlock.

803 454 / Ref. 803 324

OM-4420 Page 19
5-7. Engine Prestart Checks

Engine Oil

Full

Diesel

Full

803 454

 Check all engine fluids daily. Fuel add oil (see maintenance label for engine oil
specifications).

Do not use gasoline. Gasoline will
Engine must be cold and on a level surface. damage engine. Cold Weather Starting
Unit is shipped with 20W break-in oil. The
automatic shutdown system stops engine if Add fresh diesel fuel before starting to pre-  To improve cold weather starting:
oil pressure is too low or coolant tempera- vent air from entering the fuel system (see Use Starting Aid switch (see Section
ture is too high. engine maintenance label for fuel specifica- 6-1).
tions). Leave filler neck empty to allow room
for expansion.
 This unit has a low oil pressure shut- Keep battery in good condition. Store
down switch. However, some condi- Engine stops if fuel level is low on units with battery in warm area.
tions may cause engine damage before low fuel shutdown option. Do not run out of
the engine shuts down. Check oil level fuel or air may enter fuel system and cause Use fuel formulated for cold weather
often and do not use the oil pressure starting problems. See engine manual to (diesel fuel can gel in cold weather).
shutdown system to monitor oil level. bleed air from fuel system. Contact local fuel supplier for fuel in-
formation.
Engine Oil
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust After fueling, check oil with unit on level sur- Use correct grade oil for cold weather
pipe during run-in, see Section 11. face. If oil is not up to full mark on dipstick, (see Section 8-2).

OM-4420 Page 20
5-8. Connecting To Weld Output Terminals

Stop engine.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
Stick And TIG Welding
For Stick welding Direct Current Electrode
Positive (DCEP), connect electrode holder
cable to Positive (+) terminal on left and work
cable to Negative (−) terminal on right.
For Stick and TIG Direct Current Electrode
Negative (DCEN), connect electrode holder
cable to Negative (−) terminal on right and work
cable to Positive (+) terminal on left.
MIG And FCAW Welding
For MIG welding Direct Current Electrode Pos-
itive (DCEP), connect wire feeder cable to
Positive (+) terminal on left and work cable to
Negative (−) terminal on right. Use Process/
Contactor switch to select type of weld output
(see Section 6-3).
For MIG and FCAW Direct Current Electrode
Negative (DCEN), connect wire feeder cable
to Negative (−) terminal on right and work cable
to Positive (+) terminal on left. Use Process/
Contactor switch to select type of weld output
(see Section 6-3).
1

Tools Needed:

3/4 in 803 452

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!

OM-4420 Page 21
5-9. 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

Turn off power 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)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0
600 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0
700 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120) (4x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0 4 ea. 4/0
800 4/0 (120)
(2x70) (2x95) (2x120) (3x120) (3x120) (4x120) (4x120)

* Chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

Notes

Work like a Pro!

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

OM-4420 Page 22
5-10. Connecting To Remote 14 Receptacle RC14

Socket* Socket Information

A 24 volts ac. Protected by circuit

breaker CB5 (see Section 8-7).
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.

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

115 volts, 10 amperes, 60 Hz

I ac. Protected by circuit breaker
OR CB6 (see Section 8-7).
115 VOLTS AC

Contact closure to I completes

J 115 volt ac contactor control
circuit.

K Chassis common.
803 452
GND

NEUTRAL G Circuit common for 24 and 115

volt ac circuit.

*The remaining sockets are not used.

Notes

OHM’S LAW
VOLTAGE =
CURRENT X RESISTANCE

CURRENT = VOLTAGE
RESISTANCE

RESISTANCE = VOLTAGE
CURRENT

OM-4420 Page 23
 SECTION 6 − OPERATING THE WELDING GENERATOR
6-1. Controls (See Section 6-2)

9 10 12 13 6 5

8 1 2
11

803 454 / 217 638-A

OM-4420 Page 24
6-2. Description Of Controls (See Section 6-1)

Engine Starting Controls scheduling maintenance. Use the highest range for MIG welding and for
1 Starting Aid Switch cutting and gouging (CAC-A).
4 Fuel Gauge
Use switch to energize starting aid for cold For most welding applications, use lowest
Use gauge to check fuel level. Engine stops amperage range possible to help prevent arc
weather starting. if fuel level is low on units with low fuel shut- outages.
Push switch up for 60 seconds to operate the down option.
starting aid (intake air heater) before cranking 10 Voltage/Amperage Adjust Control
To check fuel level when engine is not run-
engine (see starting instructions following). ning, turn Engine Control switch to Run/Idle With Process/Contactor switch in any Stick or
2 Engine Control Switch position. TIG setting, use control to adjust amperage
within range selected by Ampere Range
Use switch to start engine, select engine 5 Engine Oil Pressure Gauge switch. With Process/Contactor switch in any
speed, and stop engine. Normal pressure is 30 − 60 psi (206 − 414 MIG position, use control to adjust voltage.
In Run position, engine runs at weld/power kPa). Engine stops if pressure is below 20 psi With Voltage/Amperage Adjust Switch in Re-
speed. In Run/Idle position, engine runs at (138 kPa). mote position, control limits the remote am-
idle speed with no generator power or weld perage in TIG mode, but has no effect in Stick
6 Engine Temperature Gauge and MIG modes.
load, and weld/power speed with load ap-
plied. Normal temperature is 212 - 239° F (100 - Weld output would be about 263 A DC with
115° C). Engine stops if temperature exceeds controls set as shown (50% of 125 to 400 A).
To Start: 270° F (132° C).
 If engine does not start, let engine come 7 Battery Voltmeter
 The numbers around the Voltage/Amper-
to a complete stop before attempting re- age Adjust control are for reference only
Use gauge to check battery voltage and moni- and do not represent an actual percent-
start.
tor the engine charging system. The meter age value.
Above 32
F (0
C): turn Engine Control should read about 14 volts dc when the en-
switch to Start. Release Engine Control gine is running, and about 12 volts dc when 11 Voltage/Amperage Adjust Switch And
switch when engine starts. the engine is stopped. Remote 14 Receptacle

Below 32
F (0
C) using starting aid Weld Controls Use switch to select front panel or remote
switch: voltage/amperage control. For remote con-
8 Process/Contactor Switch trol, place switch in Remote position and con-
Turn Engine Control switch to Run/Idle posi-
tion. Push Starting Aid switch up for 60 sec- See Section 6-3 for Process/Contactor nect remote control to Remote 14 receptacle
onds. While still holding Starting Aid switch, switch information. RC14 (see Sections 5-10 and 6-4).
turn Engine Control switch to Start. Release 9 Ampere Range Switch Weld Meters
Engine Control switch and Starting Aid switch

Do not switch under load. 12 AC/DC Voltmeter (Optional)
when engine starts.
Use switch to select weld amperage range. Voltmeter displays voltage at the weld output
To Stop: turn Engine Control switch to Off
terminals, but not necessarily the welding arc
position.
Use all five ranges for Stick welding, and the due to resistance of cable and connections.
Engine Gauges lowest four ranges for TIG welding. Read the
13 AC/DC Ammeter (Optional)
upper set of numbers at each range for Stick
3 Engine Hour Meter
welding and the lower set at each range for Ammeter displays amperage output of the
Use gauge to monitor engine running time for TIG welding. unit.

OM-4420 Page 25
6-3. Process/Contactor Switch
1 Process/Contactor Switch

Weld output terminals are ener-
gized when Process/Contactor
switch is in a Weld Terminals Al-
ways On position and the en-
gine is running.

DC voltage is still present at the
weld terminals when Process/
1 Contactor switch is in the Re-
mote On/Off Switch Required −
Stick position and the engine is
running.
Use switch to select weld process and
weld output on/off control (see table be-
low and Section 6-4).
Place switch in Remote On/Off Switch
Required positions to turn weld output
on and off with a device connected to
the remote 14 receptacle.
Place switch in Weld Terminals Always
On 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 addition-
al amperage during low voltage (short
arc length conditions) to prevent “stick-
ing” electrodes.
The arc drive (dig) circuit is disabled
when switch is in MIG or TIG positions.

 The engine auto idle option does

not work in the Remote On/Off
Switch Required-TIG mode.

217 638-A

Process/Contactor Switch Settings

Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)

Remote On/Off Switch Re-

GTAW With HF Unit, Pulsing
quired − TIG, HF Required At Remote 14 Receptacle Not Active
Device, Or Remote Control
Or Scratch Start TIG

Remote On/Off Switch

Stick (SMAW) With Remote On/Off At Remote 14 Receptacle Active
Required − Stick

Remote On/Off Switch

Required − CV Feeder MIG (GMAW) At Remote 14 Receptacle Active
Using Remote

Weld Terminals Always On −

MIG (GMAW) Electrode Hot Active
Wire

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

Weld Terminals Always On −

TIG Scratch Start (GTAW) Electrode Hot Active
TIG, Scratch Start

OM-4420 Page 26
6-4. Using Remote Voltage/Amperage Control
1 Remote 14 Receptacle RC14
Connect optional remote control to
RC14 (see Section 5-10).

803 454

Example: Combination Remote Amperage Control (Stick) In Example:

Process = Stick (Using Remote On/Off)
Range = 125 to 400 A DC
Min = 125 A DC
Max = 400 A DC

Max (400 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 330 A DC
Percentage Of Range = 50%
Min = 40 A DC
Max = About 185 A DC (50% of 40 to 330)

Max (185 A DC)

Min (40 A DC)

Set V/A Set Remote
Set Range Set Control Adjust Optional Remote Control
Adjust Switch Process

0774 / Ref. 217 638-A / 802 311-A

OM-4420 Page 27
 SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. 120 Volt And 240 Volt Receptacles

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

OM-4420 Page 28
7-2. Optional Generator Power Receptacles
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
6 Circuit Breaker CB3
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
6 work. Place 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

OM-4420 Page 29
 SECTION 8 − ENGINE/GENERATOR MAINTENANCE
Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.

8-1. Routine Engine/Generator Maintenance

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 often if used in severe
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 5-7.
Section 8-6.

Every 50 h

Clean And
Clean Engine
Tighten Weld
Air Filter.
Terminals.
See Section 8-3.

Every 100 h

Check Engine Air Clean And

Cleaner Hoses Tighten
For Cracks And Battery
Loose Clamps. Connections.

Every 250 h

Inspect
Replace 1/2 in. Belts And
Unreadable (13 mm)
Check
Labels. Tension.

Check And
Clean Clean Optional
Radiator. Spark Arrestor.
See Section 8-4.

Every 500 h

Change Engine Oil

Change Engine Oil. Filter. See Section 8-6.
See Section 8-6. Service more often in
dirty conditions.

Repair Or
Replace
Cracked
Cables.

OM-4420 Page 30
 Every 1000 h
Service Welding
Change Engine Generator Brushes
Fuel Filters. And Slip Rings.
See Section Service More Often
8-6. In Dirty Conditions.*

Drain Sludge
FUEL From Fuel Check
Tank. See Engine Valve
SLUDGE Section 8-6. Clearance.*

Blow Out Or
Vacuum Inside.
OR During Heavy
Service,
Clean Monthly.

Every 3000 h

Clean/Set
Engine Fuel
Injectors.*

Every 6000 h / 5 Years

Replace
Engine
Timing Belt.

OM-4420 Page 31
8-2. Engine Maintenance Label

OM-4420 Page 32
8-3. Servicing Air Cleaner

Stop engine.

Do not run engine without air
cleaner or with dirty element. En-
gine damage caused by using a
damaged element is not covered
by the warranty.
1 Engine Air Cleaner
 The air cleaner primary element can
be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.

If you decide to clean the primary ele-

1 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
2 3 4 5 (see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
2 Housing
3 Safety Element (Optional)
4 Primary Element
5 Dust Cap
Optional
6 Dust Ejector
6
To clean air filter:
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.

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
Keep nozzle
inside of element. Replace primary ele-
2 in (51 mm)
ment if it has holes or damaged gaskets.
from element.
Reinstall primary element and cap (dust
ejector down).

Blow Inspect

aircleaner1 9/00 − 803 454 / 153 929-B / 153 585 / Ref. S-0698-B

OM-4420 Page 33
8-4. Inspecting/Cleaning Optional Spark Arrestor Muffler

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

Tools Needed:
3/8 in 803 452 / 803 230

OM-4420 Page 34
8-5. Adjusting Engine Speed

Stop engine and let cool.
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.
Turn Process/Contactor switch to
Stick − Weld Terminals Always On
position.
1 Throttle Rod
2 Locknut
Loosen locknuts. Place engine
control switch in Run/Idle position.
Wait 15 seconds for throttle sole-
noid to energize and lower engine
speed to idle rpm.
Turn throttle rod to adjust idle
speed. Tighten locknuts.
3 Engine Speed Adjustment
Screw
4 Locknut
Place engine control switch in Run
position.
Loosen locknut. Turn screw to ad-
just weld/power speed. Tighten
locknut.

 Do not set engine speed higher

than specified.

Stop engine.
Close door.

1850 rpm Max.

(61.6 Hz)
1235 rpm
2 (41.1 Hz)
1
2

Tools Needed:

3/8, 7/16 in
803 454 / 802 313-A

OM-4420 Page 35
8-6. Servicing Engine Fuel And Lubrication Systems

Tools Needed:

6
2

803 454

Stop engine and let cool. base. See engine manual and engine main- To replace secondary fuel filter:
tenance label for oil specifications. See engine manual.

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

OM-4420 Page 36
8-7. Engine/Generator Overload Protection

Stop engine.

 When a circuit breaker or fuse

opens, it usually indicates a more
serious problem exists. Contact
Factory Authorized Service Agent.
1 Fuse F1
2 Fuse F2
F1 and F2 protect the stator exciter
winding 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 gen-
erator power is still available.
3 Circuit Breaker CB4 (Not Shown)
4 Circuit Breaker CB5
5 Circuit Breaker CB6
2 1
6 Circuit Breaker CB10 (Not
Shown)
7 Circuit Breaker CB11
8 Circuit Breaker CB12
9 Circuit Breaker CB13
10 Circuit Breaker CB14
9
(Not Shown)
8
7 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 out-
put to field current regulator board PC1.
If CB5 opens, weld output and 24 volt
output to RC14 stops. On units with op-
tional power plant, power at receptacle
RC5 also stops if CB5 opens.
4 5
CB6 protects the 115 volt ac output to
remote receptacle RC14. If CB6 opens,
115 volt output to RC14 stops.
CB10 protects the engine battery cir-
cuit. If CB10 opens, the engine will not
crank. CB10 automatically resets when
the fault is corrected.
CB11 protects the engine wiring har-
ness. If CB11 opens, weld output stops
(generator power is still available).
CB12 protects the field flashing circuit.
If CB12 opens, the generator may not
excite at start-up and weld and genera-
tor power output may not be available.
CB13 protects the engine shutdown cir-
cuit. If CB13 opens, the engine cranks
but does not start.
Press button to reset breaker.
CB14 protects the throttle solenoid. If
CB14 opens, the engine will not run at
idle speed. CB14 automatically resets
when the fault is corrected.

Ref. 803 229

OM-4420 Page 37
 SECTION 9 − TROUBLESHOOTING
9-1. Troubleshooting Tables

A. Welding

Trouble Remedy

No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at ac receptacles. position and connect remote contactor to Remote 14 receptacle RC14 (see Sections 5-10 and 6-1).

Check position of Ampere Range switch.

Reset circuit breaker CB11 (see Section 8-7).

Reset circuit breaker CB5 (see Section 8-7). Check for faulty remote device connected to RC14.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-10).

Have Factory Authorized Service Agent check connector board PC6 and connections.

Check fuse F2, and replace if open (see Section 8-7). 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 Disconnect equipment from generator power receptacles during start-up.
output.

Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

Reset circuit breaker CB12 (see Section 8-7).

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

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

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Have Factory Authorized Service Agent check brushes and slip rings.

High weld output. Check position of Ampere Range switch and Voltage/Amperage Adjust control.

Check engine weld/power speed, and adjust if necessary (see Section 8-5).

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 position of Ampere Range switch and Voltage/Amperage Adjust control.

Check engine weld/power speed, and adjust if necessary (see Section 8-5).

Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service 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 8-7).
frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.
length) conditions.

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

Check position of Process/Contactor switch.

OM-4420 Page 38
 Trouble Remedy

No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position.
control.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-10).

Repair or replace remote control device.

Have Factory Authorized Service Agent check PC1 current sensing leads (36 and 37), and connections.

Constant speed wire feeder does not Reset circuit breaker(s) CB5 and CB13 (see Section 8-7).
work.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-10).

Repair or replace wire feeder.

Low CV weld output. Set Ampere Range switch to highest range.

Increase Voltage/Amperage Adjust Control setting.

Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.

Repair or replace remote control device.

Have Factory Authorized Service Agent check field current regulator board PC1.

B. Generator Power

Trouble Remedy

No generator power output at ac recep- Reset receptacle circuit breakers.

tacles; weld output okay.

Reset GFCI receptacle.

No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.

Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, diode/capacitor board D1/C1, and the rotor.

Reset circuit breaker CB12. Have Factory Authorized Service Agent check field current regulator board
PC1 (see Section 8-7).

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

High output at generator power Check engine weld/power speed, and adjust if necessary (see Section 8-5).
receptacles.

Have Factory Authorized Service Agent adjust field current resistor R3.

Low output at generator power Check engine weld/power speed, and adjust if necessary (see Section 8-5).
receptacles.

Check fuse F1, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check inte-
grated rectifier SR1, resistor R3, and capacitor C9.

C. 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 8-7).
Have Factory Authorized Service Agent check engine wiring harness and components.

Check engine wiring harness plug connections.

Turn optional battery disconnect switch to On position (see Section 5-6).

Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, and diode/
capacitor board D8/C8.

OM-4420 Page 39
 Trouble Remedy

Engine cranks but does not start. Check fuel level. Optional low fuel shutdown stops engine if fuel level is low.

Reset circuit breaker CB13 (see Section 8-7). Have Factory Authorized Service Agent check engine wir-
ing harness and components.

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

Have Factory Authorized Service Agent check time delay relay TD1, control relay CR5, fuel pump,
and fuel solenoid FS1.

Air in fuel system. See engine manual.

Engine starts, but stops when Engine Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
Control switch is released. is too high (see Section 5-7).

Have Factory Authorized Service Agent check time delay relay TD1, and control relay CR5.

Engine hard to start in cold weather. Use starting aid switch (see Section 6-1). If Starting Aid switch does not work have Factory Authorized
Service Agent check Engine Control switch S2, and control relay CR8.

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

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

Use correct grade oil for cold weather (see Section 8-2 ).

Engine suddenly stops. Check fuel level. Optional low fuel shutdown stops engine if fuel level is low.

Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Section 5-7).

Have Factory Authorized Service Agent check time delay relay TD1, control relay CR5, fuel pump,
and fuel solenoid FS1.

See engine manual.

Engine slowly stopped and cannot be Check fuel level.

restarted.

Check engine air and fuel filters (see Sections 8-3 and 8-6).

See engine manual.

Battery discharges between uses. Turn Engine Control switch S1 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.

Check for obstructed throttle solenoid.

Engine does not run at idle speed. Turn Process/Contactor switch to 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 8-7).

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 11).
wetstacking occurs.

OM-4420 Page 40
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!
OM-4420 Page 41
 SECTION 10 − ELECTRICAL DIAGRAM

Figure 10-1. Circuit Diagram For Welding Generator

OM-4420 Page 42
 217 852-C

OM-4420 Page 43
 SECTION 11 − RUN-IN PROCEDURE
run_in1 8/01

11-1. 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.

OM-4420 Page 44
11-2. 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.

Do not perform run-in
2 procedure at less than 20
volts weld output and do not
1 exceed duty cycle or equip-
ment damage may occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe correct
polarity.
Start engine and run for several
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.

Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0683

OM-4420 Page 45
11-3. 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.

Do not perform run-in
2 procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
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.

Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0684

OM-4420 Page 46
 SECTION 12 − 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.

12-1. 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

12-2. 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)
3 Metal Vehicle Frame
1
Connect cable from equipment
GND/PE 2 ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.

If unit does not have GFCI re-
ceptacles, use GFCI-pro-
3 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

OM-4420 Page 47
12-3. 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

12-4. 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 12-8).
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

OM-4420 Page 48
12-5. 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

12-6. Approximate Power Requirements For Farm/Home Equipment

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

OM-4420 Page 49
12-7. Approximate Power Requirements For Contractor Equipment
Contractor Rating Starting Watts Running Watts
Hand Drill 1/4 in 350 350
3/8 in 400 400
1/2 in 600 600
Circular Saw 6-1/2 in 500 500
7-1/4 in 900 900
8-1/4 in 1400 1400
Table Saw 9 in 4500 1500
10 in 6300 1800
Band Saw 14 in 2500 1100
Bench Grinder 6 in 1720 720
8 in 3900 1400
10 in 5200 1600
Air Compressor 1/2 HP 3000 1000
1 HP 6000 1500
1-1/2 HP 8200 2200
2 HP 10500 2800
Electric Chain Saw 1-1/2 HP, 12 in 1100 1100
2 HP, 14 in 1100 1100
Electric Trimmer Standard 9 in 350 350
Heavy Duty 12 in 500 500
Electric Cultivator 1/3 HP 2100 700
Elec. Hedge Trimmer 18 in 400 400
Flood Lights HID 125 100
Metal Halide 313 250
Mercury 1000
Sodium 1400
Vapor 1250 1000
Submersible Pump 400 gph 600 200
Centrifugal Pump 900 gph 900 500
Floor Polisher 3/4 HP, 16 in 4500 1400
1 HP, 20 in 6100 1600
High Pressure Washer 1/2 HP 3150 950
3/4 HP 4500 1400
1 HP 6100 1600
55 gal Drum Mixer 1/4 HP 1900 700
Wet & Dry Vac 1.7 HP 900 900
2-1/2 HP 1300 1300

OM-4420 Page 50
12-8. 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

12-9. 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

OM-4420 Page 51
12-10. 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 12-4).

Notes

Work like a Pro!

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

OM-4420 Page 52
12-11. 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

OM-4420 Page 53
 SECTION 13 − SELECTING AND PREPARING
TUNGSTEN ELECTRODE
gtaw 7/97

NOTE For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent
contamination of tungsten electrode.

13-1. Selecting Tungsten Electrode

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter DC − Argon − Electrode DC − Argon − Electrode AC − Argon − Using AC − Argon − Balanced
Negative/Straight Polarity Positive/Reverse Polarity High Frequency Wave Using High Freq.
Pure Tungsten
(Green Band)
.010” Up to 15 * Up to 15 Up to 10
.020” 5-20 * 5-20 10-20
.040” 15-80 * 10-60 20-30
1/16” 70-150 10-20 50-100 30-80
3/32” 125-225 15-30 100-160 60-130
1/8” 225-360 25-40 150-210 100-180
5/32” 360-450 40-55 200-275 160-240
3/16” 450-720 55-80 250-350 190-300
1/4” 720-950 80-125 325-450 250-400
2% Thorium Alloyed
Tungsten (Red Band)
.010” Up to 25 * Up to 20 Up to 15
.020” 15-40 * 15-35 5-20
.040” 25-85 * 20-80 20-60
1/16” 50-160 10-20 50-150 60-120
3/32” 135-235 15-30 130-250 100-180
1/8” 250-400 25-40 225-360 160-250
5/32” 400-500 40-55 300-450 200-320
3/16” 500-750 55-80 400-500 290-390
1/4” 750-1000 80-125 600-800 340-525
Zirconium Alloyed Tung-
sten (Brown Band)
.010” * * Up to 20 Up to 15
.020” * * 15-35 5-20
.040” * * 20-80 20-60
1/16” * * 50-150 60-120
3/32” * * 130-250 100-180
1/8” * * 225-360 160-250
5/32” * * 300-450 200-320
3/16” * * 400-550 290-390
1/4” * * 600-800 340-525

♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
OM-4420 Page 54
13-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding
1 Tungsten Electrode
2 Balled End

Understand and follow
1 safety symbols at start of
Section 14-1 before pre-
paring tungsten.
Ball end of tungsten before welding
1-1/2 Times by applying either an ac amperage
Electrode Diameter
slightly higher than what is recom-
mended for a given electrode diam-
eter (see Section 13-1), or a dc
2 electrode positive amperage.

Ref. S-0161

13-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding

1 Tungsten Electrode
1 2 2 Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld-
ing. Do not use wheel for other jobs
or tungsten can become contami-
nated causing lower weld quality.

2-1/2 Times
Electrode Diameter

1 Stable Arc
2 Flat
1
Diameter of this flat determines
amperage capacity.
2
3 Grinding Wheel
3 4 Straight Ground

4
Ideal Tungsten Preparation − Stable Arc

1 Arc Wander
2 Point
1 3 Grinding Wheel
4 Radial Ground
2

Wrong Tungsten Preparation − Wandering Arc

Ref. S-0161 / Ref. S-0162

OM-4420 Page 55
 SECTION 14 − GUIDELINES FOR TIG WELDING (GTAW)
14-1. Positioning The Torch

Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
3
1 Workpiece
Make sure workpiece is clean
2 before welding.
2 Work Clamp
Place as close to the weld as
4 possible.
3 Torch
4 Filler Rod (If Applicable)
90° 5 Tungsten Electrode
1 Select and prepare tungsten
according to Sections 13-1, and
13-2 or 13-3.
Tungsten extension is the distance
the tungsten extends out gas cup of
torch.
Arc length is the distance from the
10−15° tungsten to the workpiece.
4 As a general guide, start with an
extension and arc length equal to
diameter of tungsten.
5
10−25°

ST-161 892

14-2. Torch Movement During Welding

Tungsten Without Filler Rod

Welding direction 75°

Form pool Tilt torch Move torch to front

of pool. Repeat process.

Tungsten With Filler Rod

75° 15°
Welding direction

Form pool Tilt torch Add filler metal

Remove rod Move torch to front

of pool. Repeat process.
ST-162 002-B

OM-4420 Page 56
14-3. Positioning Torch Tungsten For Various Weld Joints

90°
Butt Weld And Stringer Bead
70°

20°

20°

“T” Joint

70°

20°
10°

40°

Lap Joint

70°

20°

30°

90°

Corner Joint
70°

20°

ST-162 003 / S-0792

OM-4420 Page 57
 SECTION 15 − PARTS LIST
 Hardware is common and not
available unless listed.

3 15
16
17

2 18
19
1

14
7 13 20
6

5 11
21
10
4
9 12 22

121
113
23
24
120
110
119 − Figure 15-5
13 104
114 112

111 − Figure 15-2

118 105

106

107

115 108
109
116

117 − Figure 15-3

Figure 15-1. Main Assembly

OM-4420 Page 58
 125
36
35
34

33

37
32 31
30
29
28
27
59
58
26
39 57
60
53 56 61
25 38 62
51 55
49
50 54
52

45
47

124
42 43
44 46 63

48 64
122 62
41
123 65
40 66
72
67
68
77 73 69
76
75 74 70
71
93 − Figure 15-4 78 79 81
87
85
94 86
97 82
95 98
96 80
99 83
88
100 84

101

91
89
92
102 90

103

803 455

OM-4420 Page 59
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-1. Main Assembly

. . . 1 . . . . . . . . . . . . . . 189824 . . Panel, Gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 189828 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 206601 . . Panel, Engine Extension LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . . . 208277 . . Reactor, AC Environmental Rda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 038620 . . Link, Jumper Term Blk 30 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 1T . . . . . 189549 . . Block, Term Assy Standard W/Clamp (includes) . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 038621 . . . . Block, Term 30 Amp 4 Pole Frict Term Str Both Side . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 081499 . . . . Bracket, Mtg Strip Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 138027 . . . . Edge Trim, Style Tl750−b2x1/16 Black W/Clips 3.750 . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 020225 . . . . Clamp, Nyl .875 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . 1
. . . 8 . . SR4, SR5 . . 035704 . . Rectifier, Integ Bridge 40 Amp 800 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . CB4 . . . . 045061 . . Circuit Breaker, Auto Reset 24vdc 7 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 206352 . . Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . T1 . . . . . 205636 . . Transformer, W/Brkt Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 201697 . . Pan, Reactor And Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 173352 . . Extrusion, Rubber (order by ft.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 189708 . . Firewall, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 194485 . . Hose, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 189764 . . Air Cleaner, Intake (Engine) (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192938 . . . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192939 . . . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206556 . . Pipe, Air Cleaner Intake Deutz (Turbo Hose To Air Cleaner Hose) . . . . . 1
. . . 17 . . . . . . . . . . . . . . 189763 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 206351 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . ♦209612 . . Lever, Switch Lockout Disconnect Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . ♦209597 . . Bracket, Mtg Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . ♦209611 . . Switch, Disc Battery 2P 6−36 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 196220 . . Bracket, Holddown Fuel Tank Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 192362 . . Bracket, Mtg Nyl 1/2 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . +206603 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 176103 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 176104 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . ♦143915 . . Mount, Sgl Stud 1.5 Dia X 1.000 Lg .312−18 Stud . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . ♦205702 . . Bracket, Mtg Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . ♦205749 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . ♦603767 . . Cap, Weather Exhaust No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . ♦010875 . . Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 35 . . . . . . . . . . . . ♦205712 . . Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . ♦205748 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . 176230 . . Label, Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . 213895 . . Manifold, Exhaust Muffler Bf4m2011 Deutz . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . 202633 . . Support, Cover E−coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . 191577 . . Guard, Starter Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 191809 . . Bracket, Mtg Engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 209632 . . Hose, Tubing Oil Assyw/Fittings 22.380lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-4420 Page 60
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-1. Main Assembly (Continued)

. . . 43 . . . . . . . . . . . . . . 218619 . . Engine, Deutz Dsl Elec Bf4m2011 (includes) . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 193256 . . . . Adapter, Engine Deutz 1011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 195748 . . . . Flywheel, Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 195746 . . . . Sender, Coolant Temp & 130c Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 195745 . . . . Switch, Pressure Oil 1.5 Bar Nc Cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067265 . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *066217 . . . . Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 208041 . . Spacer, Stl .323 Id X .625 Od X .141 Thk (Alternator) . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193230 . . Sender, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 194403 . . Adaptor, Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . GLOW PLUG . 190059 . . Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 207203 . . Fan, Engine Cooling 18.000 Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 208042 . . Spacer, Stl .800id X 1.188od X .090 Thk (Fan Hub Bolt) . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . *207808 . . Belt, V .375 X 45.125 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 209675 . . Extension, Hydraulic 37 Deg Flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . 209633 . . Hose, Tubing Oil Assyw/Fittings 27.040lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . 209621 . . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . 207269 . . Guard, Fan LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . 206749 . . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . 206558 . . Cooler, Oil Engine/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . 209623 . . Ftg, Brs Adapter Long 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . 201749 . . Upright, Rear Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . . 201006 . . Bolt, J Stl .312−18 X 7.750 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 55 . . . . BATT . . . . 190897 . . Battery, Stor 12v 650 Crk 110 Rsv Gp 24 Maint Free . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . 108081 . . Terminal Protector, Battery Post Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 57 . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . 203430 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . +201183 . . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . 176108 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 176106 . . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . 8
. . . 63 . . . . . . . . . . . . . +206602 . . Panel, Engine Extension R.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 212286 . . Guard, Fan RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . 199849 . . Screw, 625−11x4.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 66 . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 67 . . . . . . . . . . . . . . 191812 . . Bracket, Mtg Engine R.h. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . 071890 . . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 69 . . . . . . . . . . . . . . 071730 . . Tubing, Stl .875 Od X12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 70 . . . . . . . . . . . . . . 083476 . . Mount, Eng/Gen Nprn .875id X 2.500od X 2.000 60 Dur . . . . . . . . . . . . . . 4
. . . 71 . . . . . . . . . . . . . . 135205 . . Nut, 625−11 .94hex .77h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . 176529 . . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.666
. . . 75 . . . . . . . . . . . . . . 176528 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 1/2 Npt . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . 173336 . . Ftg, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . 066298 . . Ring (Oil Drain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . . 218003 . . Bracket, Mtg Fuel Filter/Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . . 206297 . . Base, Fuel Filter Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . *192744 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 199383 . . Hose, Sae .312 Id X .560 Od X 8.000 (Fuel Filter To Fuel Pump) . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 191819 . . Hose, Sae .312 Id X .560 Od X 14.000 (Fuel Tank To Fuel Filter) . . . . . . 1

OM-4420 Page 61
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-1. Main Assembly (Continued)

. . . 81 . . . . . . . . . . . . . . 174064 . . Idle, Solenoid Assy (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 196036 . . . . Bracket, Arm Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 125663 . . . . Ball Joint, .250−28 Type Sp Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 175936 . . . . Rod, Throttle 5.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 127994 . . . . Ball Joint, .250−28 Type Spf Female Rod End . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 127648 . . . . Clevis, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 124974 . . . . Solenoid, 12vdc Pull/Hold Type 1” Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 601868 . . . . Nut, 250−28 .44hex .26h Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 126388 . . . . Nut, 250−28 .44hex .27h Stl Pld Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 089800 . . . . Nut, 250−20 .44hex .22h Stl Pld .58d Flange Defor . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 108941 . . . . Screw, 250−20x1.00 Hexwhd.61d Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 156733 . . . . Nut, 250−28 .44hex .13h Stl Pld Sem Cone Wshr.51d . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . . 190992 . . Keeper, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . . 085963 . . Spring, Ext .375 Od X .041 Wire X 2.000 (ForSafety Latch) . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . . 206604 . . Channel, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . . . . . 199592 . . Latch, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . +200 989 . . Door, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . . 206464 . . Label, Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . 189 975 . . Hinge, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 89 . . . . . . . . . . . . . 208 141 . . Stop, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 90 . . . . . . . . . . . . . 189 826 . . Panel, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 92 . . . . . . . . . . . . . +189827 . . Panel, Gen Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . Figure 15-4 . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . . 218087 . . Tank, Fuel (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 96 . . . . . . . . . . . . . . 189912 . . . . Ftg, Stl Barbed Elbow W/.047in Orifice Zinc Pld . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . . . . . 189909 . . . . Ftg, Stand Pipe Hose .250 X 9.265lg 90 Deg Zinc . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . . . . . . . . . 189913 . . . . Ftg, Stl Barbed Elbow Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . . 190142 . . . . Sender, Fuel Gauge 9.750 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . . 189910 . . . . Ftg, Stand Pipe Hose .3125 X 9.260lg 90 Deg Zinc . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . . . 181572 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196219 . . Hose, Sae .250 Id X .500 Od X 26.000 (Fuel Return Line) . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . . 191446 . . Extrusion, Rubber w/Adhesive 1.000 x 1.000 (order by ft.) . . . . . . . . . . . . 6ft
. . 104 . . . . . . . . . . . . . 209094 . . Bracket, Mtg Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . . +212224 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . . . 191897 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 107 . . . . . . . . . . . . . 200864 . . Label, Do Not Weld On Base CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 108 . . . . . . . . . . . . . 212046 . . Label, Manufacturing Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . . R3 . . . . . 189699 . . Resistor, WW Tap 375 W 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . 1
. . 110 . . . . . . . . . . . . . 218086 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . . . . . . . . Figure 15-2 . . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 112 . . . . . . . . . . . . . 189731 . . Firewall, Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 113 . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 114 . . . . . . . . . . . . . 191448 . . Cover, Top Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 115 . . . . . . . . . . . . . 201750 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 116 . . . . . . . . . . . . . 182761 . . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 117 . . . . . . . . . Figure 15-3 . . Panel, Front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 118 . . . CT1 . . ♦202130 . . Xfmr, Current Sensing (Auto Idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 119 . . . . . . . . . Figure 15-5 . . Main Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 120 . . . . . . . . . . . . . 193453 . . Bracket, Mtg Box Fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 121 . . . PC1 . . . . 207397 . . Module, Field Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 122 . . . . . . . . . . . . . 208024 . . Pulley, Fan Assy W/Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 123 . . . . . . . . . . . . . 206613 . . Bracket, Mtg Fan/Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 124 . . . . . . . . . . . . . 213896 . . Spacer, Stl 1.250 X.375 .531 Hole Dia (Muffler) . . . . . . . . . . . . . . . . . . . . . . 1
. . 125 . . . . . . . . . . . . . 105734 . . Pipe, Muffler Extension Elbow 1.750 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4420 Page 62
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-1. Main Assembly (Continued)

. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 212045 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . ♦195118 . . Kit, Lock-Out Vandalism (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209238 . . . . Door, Access Rh W/Om Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209240 . . . . Door, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209236 . . . . Tab, Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209241 . . . . Mount, Access Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦209242 . . . . Mount, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦189975 . . . . Hinge, Door Access 180 Deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . ♦155146 . . . . Sponge, Nprn .060 X 1.000 Wide X 4.000 Sce 41 Close . . . . . . . . . . . . 3

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 212 045.
* Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

10

5
11

21
4

20

19

2 14
1
17
15
16
22
7
6 19 12

9
18

13

803 456-A

Figure 15-2. Control Box Assembly

OM-4420 Page 63
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-2. Control Box Assembly − (Figure 15-1 Item 111)

. . . 1 . . . F1, F2 . . . 085874 . . Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . . 046432 . . Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 3
. . . 4 . . . . PC9 . . . . 192224 . . Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 201077 . . Control Box, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206736 . . Harness, Control Box, Weld Control LH (includes) . . . . . . . . . . . . . . . . . . . 1
. . . 6 . CB11, CB12,CB13 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . 3
. . . 7 . . . . SR1 . . . . 035704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC3 . . . . 158466 . . . . Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . 1
. . . . . . . . . . RC1 . . . . 135133 . . . . Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1
. . . 8 . . . . . C9 . . . . . 087110 . . Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 177136 . . Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 204737 . . Cable Tie Mount, Winged Push . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 10 . . . . . . . . . . . . . . 201078 . . Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . CR3, CR6 . . 090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . PC7 . . . . 195706 . . Module, Pull To Idle, Two Output, 7 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . TD1 . . . . 214928 . . Timer, Delay On Make/Break Open 30 Sec 12vdc . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . +201079 . . Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 217823 . . Label, Layout Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 217815 . . Harness, Engine Deutz Bf4m2011 (includes) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CB10 . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 156734 . . . . Nut, 010−32 .31hex .13h Stl Pld Sem Cone Wshr.38d . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 17 . . . . CB14 . . . . 205927 . . . . Circuit Breaker, Auto Reset 12vdc 12 Amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S2 . . . . . 021467 . . . . Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located On Front Panel, See Figure 15-3) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 211292 . . . . Conn, Pack 4p 1row Female (For Ignition Switch S1) . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 211293 . . . . Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . CR4,CR10 . 113247 . . . . Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip,Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . C1/D1,C8/D8 . 189701 . . . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C10/D10, C14/D14
. . . 20 . . . . CR1 . . . . 214876 . . . . Relay, Encl 6 vdc spst 35A/14 vdc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . CR8 . . . . 197325 . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . CR5 . . . . 199999 . . Relay, Encl 12vdc Dpst−no 30a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . . . 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.

OM-4420 Page 64
 Hardware is common and
not available unless listed.

4
3

1 5
6
10
7
8
9

47 11
46 13
12 14
45
15
44 16

17
43
42

41
22 20
40 34 19
35
39 36
38 24 21
37 25
23 18

26 27

28
33

32

31
30
29
803 457
Figure 15-3. Panel, Front w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 15-3. Panel, Front w/Components (Figure 15-1 Item 117)

... 1 . . . . . . . . . . . . . . 217638 .. Plate, Screened Ident Control (Order By Model And Serial Number) . . . . 1
... 2 . . . . . . . . . . . . . . 215014 .. Panel, Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . CT3 . . ♦209274 .. Xfmr, Current (Meters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . S3 . . . . . 208278 .. Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-4420 Page 65
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-3. Panel, Front w/Components (Continued)

. . . . . . . . . . . . . . . . . . . . 192558 . . Harness, Range Switch (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . RC6 . . . . 148389 . . . . Conn, Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 206809 . . Harness, Weld Control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . S6 . . . . . 193234 . . . . Switch, Rotary 6 Position Gold Contacts . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197527 . . . . Guard, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . S5 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196603 . . . . Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG14 . . . 141450 . . . . Conn, Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip,Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG10 . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . CB5 . . . . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB6 . . . . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon .221 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . PC6 . . . . 192995 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S1 . . . . . 212436 . . Switch, Ignition 4 Position W/Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . S2 . . . . . 021467 . . Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term (Included In Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness, See Figure Figure 15-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB1 . . . . 201083 . . Circuit Breaker, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201553 . . Clip, Retaining Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201109 . . Harness, Receptacle Auxillary Power (includes) . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB2 . . . . 093996 . . . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . GFCI1 . . . 151981 . . . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . RC1 . . . . 147632 . . . . Rcpt,Tw Lk Grd 2p3w 30a 250v *L6−30r . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 010146 . . . . Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . . . . +215347 . . Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 19 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 20 . . . . . . . . . . . . . . 163167 . . Washer, Lock .254idx0.489odx.062t Sst Split.250 . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 200910 . . Label, Warning Electric Shock And Moving Parts Ce . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle 2.250 Dia. Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . . 201125 . . Panel, Mtg Terminal Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . PC4, PC5 . . 189744 . . Circuit Card Assembly, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . S12 . . ♦220491 . . Switch, Polarity/AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 29 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 8
. . . 30 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 31 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 32 . . . . . . . . . . . . ♦059773 . . Handle, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . ♦010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 36 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . HM1 . . . . 210424 . . Meter, Hour 12−24vdc (Snap−in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . FUEL . . . . 192265 . . Gauge, Fuel Elec Switch W/O Switchgage Sensor . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . BAT . . . . 193228 . . Meter, Volt DC 8 − 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . TEMP . . . 217084 . . Gauge, Coolant Temp 0− 300 Deg F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . OIL . . . . . 217083 . . Gauge, Pressure Oil 0−100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . A1 . . . ♦164873 . . Meter, Amp AC/DC 0− 500 0−600 Dc Scale 2.5 In . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . V1 . . . ♦164874 . . Meter, Volt AC/DC 0− 100 Scale 2.5 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 189161 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4420 Page 66
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-3. Panel, Front w/Components (Continued)

. . . 47 . . . . . . . . . . . . . . 097924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . 1

.................... 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 215207 . . Harness, Unit Weld Control − CV (includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114063 . . . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . . 193184 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 147992 . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . . 158465 . . . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1
.................... 088731 . . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
.................... 135873 . . . . Clip, Conduit Convoluted 1/2 In 6.35mm Mtg Hole . . . . . . . . . . . . . . . . . 3
.................... 187654 . . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 196602 . . . . Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . 7
.................... 059712 . . Clip, Component .437 Dia Mtg Adh Back . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 024103 . . Blank, Snap−in Nyl .750 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 120304 . . Blank, Snap−in Nyl .250 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 025234 . . Plug, Str Grd 2p3w 15a 250v *6−15p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 212 045
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

11 15
16

14
17
13 18
10 12

19
8
20
21
7
6

5
3 22
4 23
24
2 26 25
1
28
27
29
30
31

32
33
34 803 327

Figure 15-4. Generator

OM-4420 Page 67
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 15-4. Generator (Figure 15-1 Item 93)

. . . 1 . . . . . . . . . . . . . . 132053 . . Screw, 375−16x1.50 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . 2 . . . . . . . . . . . . . . 183387 . . Washer, Cone .380idx .860odx.109t Stl Pld 4000lbs . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 195911 . . Endbell, Gen (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 143220 . . . . O-Ring 2.859 ID X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . AUX STATOR . 201099 . . Stator, Exciter/Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . STATOR . . +208287 . . Stator, Weld Assy Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 176106 . . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . 8
. . . 8 . . . . . . . . . . . . . . 190197 . . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 172674 . . Spring, Ext .240 Od X .041 Wire X 3.500 Pld . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 039207 . . Baffle, Air Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . ROTOR . . . 210446 . . Rotor, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 024617 . . . . Ring, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 210447 . . . . Fan, Rotor Assy Generator (Segmented) (includes) . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 210332 . . . . . . Plate, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 206242 . . . . . . Fan, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . . 049026 . . . . . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 18 . . . . . . . . . . . . . . 083883 . . . . . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . 10
. . . 19 . . . . . . . . . . . . . . 080389 . . . . . . Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . 8
. . . 20 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 4
. . . 21 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 22 . . . . . . . . . . . . . . 191579 . . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 6
. . . 24 . . . . . . . . . . . . . . 172555 . . Screw, M10−1.5x 50 Hex Hd−pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 25 . . . . . . . . . . . . . . 602159 . . Screw, 312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . . . . . 6
. . . 26 . . . . . . . . . . . . . . 604950 . . Screw, 312−18x2.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 27 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 4
. . . 28 . . . . . . . . . . . . . . 139341 . . Washer, Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 29 . . . . . . . . . . . . . *190823 . . Brush, Contact Elect .250 X.500 X 1.250 Grd Ay . . . . . . . . . . . . . . . . . . . . 3
. . . 30 . . . . . . . . . . . . . . 188560 . . Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 31 . . . . . . . . . . . . . . 189142 . . Brushholder, Generator (Brushes Not Included − See Item 29) . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 602242 . . Washer, Flat .375idx0.875odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 2
. . . 34 . . . . . . . . . . . . . . 604534 . . Screw, 312−18x1.25 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2

+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 212 045.
*Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4420 Page 68
  Hardware is common and
not available unless listed.

1
5

802 279-A

Figure 15-5. Main Rectifier Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 15-5. Main Rectifier Assembly (Figure 15-1 Item 119)

. . . . . . . . . . SR3 . . . . 215909 . . Rectifier Complete (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 1 .............. 188137 . . . . Connection Board, Rectifier Ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .............. 188517 . . . . Bus Bar, Conn Bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 3 .............. 188135 . . . . Enclosure, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 .............. 134201 . . . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . 3
. . . 5 . . . . PC3 . . . . 215755 . . . . Circuit Card Assy, Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .............. 188136 . . . . Insulator, Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
... 7 .............. 188493 . . . . Heat Sink, Rectifier Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . D3, D5, D7 . 037956 . . . . Diode, Rect 275. A 300v Sp Do−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 . 037957 . . . . Diode, Rect 275. A 300v Rp Do−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4420 Page 69
 Effective January 1, 2004
(Equipment with a serial number preface of “LE” 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 to
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
for your local the effective date of this limited warranty is free of defects in * Remote Controls
material and workmanship at the time it is shipped by Miller.
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory Kits
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
Your distributor also gives replace any warranted parts or components that fail due to such
* Canvas Covers
you ... defects in material or workmanship. Miller must be notified in Miller’s True Blue Limited Warranty shall not apply to:
Service writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings,
reliable response you relays or parts that fail due to normal wear. (Exception:
need. Most replacement Miller shall honor warranty claims on warranted equipment brushes, slip rings, and relays are covered on Bobcat,
parts can be in your listed below in the event of such a failure within the warranty Trailblazer, and Legend models.)
time periods. All warranty time periods start on the date that the
hands in 24 hours. equipment was delivered to the original retail purchaser, or one 2. Items furnished by Miller, but manufactured by others,
Support year after the equipment is sent to a North American distributor such as engines or trade accessories. These items are
Need fast answers to the or eighteen months after the equipment is sent to an covered by the manufacturer’s warranty, if any.
International distributor.
tough welding questions? 3. Equipment that has been modified by any party other than
Contact your distributor. 1. 5 Years Parts — 3 Years Labor Miller, or equipment that has been improperly installed,
The expertise of the * Original main power rectifiers improperly operated or misused based upon industry
distributor and Miller is * Inverters (input and output rectifiers only)
standards, or equipment which has not had reasonable
there to help you, every and necessary maintenance, or equipment which has
step of the way. 2. 3 Years — Parts and Labor been used for operation outside of the specifications for the
equipment.
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Semi-Automatic and Automatic Wire Feeders PERSONS TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated) 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)
* Maxstar 150 replacement; or, where authorized in writing by Miller in
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
3. 1 Year — Parts and Labor Unless Specified customer’s risk and expense. Miller’s option of repair or
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
* Motor Driven Guns (w/exception of Spoolmate Miller. Therefore no compensation or reimbursement for
Spoolguns) transportation costs of any kind will be allowed.
* Process Controllers TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Positioners and Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
* RFCS Foot Controls CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources and Coolers
ANY OTHER LEGAL THEORY.
* Water Coolant Systems (Non-Integrated)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Flowgauge and Flowmeter Regulators (No Labor) ANY IMPLIED WARRANTY, GUARANTY OR
* HF Units REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Maxstar 85, 140 PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Spot Welders OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Load Banks MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Arc Stud Power Sources & Arc Stud Guns PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Racks FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
Models)
special or consequential damages, so the above limitation or
* Field Options exclusion may not apply to you. This warranty provides specific
(NOTE: Field options are covered under True legal rights, and other rights may be available, but may vary
Blue for the remaining warranty period of the 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 be
* MIG Guns/TIG Torches available, but may vary from province to province.
miller_warr 6/04
 Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters −
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
To locate a Distributor or Service Agency visit FAX: 44 (0) 1204-598066
www.millerwelds.com or call 1-800-4-A-Miller 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  2004 Miller Electric Mfg. Co. 10/04