OM-225590E

2009−12

Processes
Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding
TIG (GTAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

Description

Dual-Operator Engine Driven Welding

Generator

Miller DU-OP
™

File: Engine Drive

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

Miller Electric manufactures a full line

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

Mil_Thank 2009−09
 TABLE OF CONTENTS

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

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. Hydraulic Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-7. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-8. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-9. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-4. Dangers liés à l’hydraulique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-5. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 13
2-7. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-8. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-9. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-2. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-5. AC Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-7. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-2. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-3. Grounding Generator To Truck Or Trailer Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-6. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-7. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-8. Safety Information For Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-9. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-10. Making Dual Operator CC Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . . 27
5-11. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . 28
5-12. Making Dual Operator CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . . . . . . . . . 29
5-13. Making Dual Operator CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-14. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables . . . . . . . . . . . . . . . . 31
5-15. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable . . . . . . . . . . . . . . . . . 32
5-16. Making Single Operator CC Weld Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-17. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5-18. Installing Ether Cylinder (Optional Ether Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5-19. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5-20. Remote 14 Receptacle Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
 TABLE OF CONTENTS

SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6-1. Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6-2. Weld Controls (See Section 6-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6-3. Weld Control Descriptions (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-1. 120 Volt And 240 Volt Duplex Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8-4. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8-6. Servicing Optional Ether Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8-7. Priming Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8-8. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8-9. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8-10. Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
WARRANTY
 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2009−10

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

1-1. Symbol Usage

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

1-2. Arc Welding Hazards

 Always verify the supply ground — check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information  When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-8. Read and tor first − double-check connections.
follow all Safety Standards.  Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and  Frequently inspect input power cord for damage or bare wiring —
repair this unit. replace cord immediately if damaged — bare wiring can kill.
 Turn off all equipment when not in use.
During operation, keep everybody, especially children, away.  Do not use worn, damaged, undersized, or poorly spliced cables.
 Do not drape cables over your body.
ELECTRIC SHOCK can kill.  If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Touching live electrical parts can cause fatal shocks or  Do not touch electrode if you are in contact with the work, ground,
severe burns. The electrode and work circuit is or another electrode from a different machine.
electrically live whenever the output is on. The input  Use only well-maintained equipment. Repair or replace damaged
power circuit and machine internal circuits are also live parts at once. Maintain unit according to manual.
when power is on. In semiautomatic or automatic wire
welding, the wire, wire reel, drive roll housing, and all  Do not touch electrode holders connected to two welding ma-
metal parts touching the welding wire are electrically chines at the same time since double open-circuit voltage will be
live. Incorrectly installed or improperly grounded present.
equipment is a hazard.  Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Do not touch live electrical parts.
 Clamp work cable with good metal-to-metal contact to workpiece
 Wear dry, hole-free insulating gloves and body protection. or worktable as near the weld as practical.
 Insulate yourself from work and ground using dry insulating mats  Insulate work clamp when not connected to workpiece to prevent
or covers big enough to prevent any physical contact with the work contact with any metal object.
or ground.  Do not connect more than one electrode or work cable to any
single weld output terminal.
 Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling. SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER stopping engine.
 Use AC output ONLY if required for the welding process.
 Stop engine on inverter and discharge input capacitors according
 If AC output is required, use remote output control if present on to instructions in Maintenance Section before touching any parts.
unit.
 Additional safety precautions are required when any of the follow- HOT PARTS can burn.
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such  Do not touch hot parts bare handed.
as floors, gratings, or scaffolds; when in cramped positions such  Allow cooling period before working on equip-
as sitting, kneeling, or lying; or when there is a high risk of unavoid- ment.
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a  To handle hot parts, use proper tools and/or wear heavy, insu-
semiautomatic DC constant voltage (wire) welder, 2) a DC manual lated welding gloves and clothing to prevent burns.
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder FLYING METAL or DIRT can injure eyes.
is recommended. And, do not work alone!
 Disconnect input power or stop engine before installing or  Welding, chipping, wire brushing, and grinding
servicing this equipment. Lockout/tagout input power according to cause sparks and flying metal. As welds cool,
OSHA 29 CFR 1910.147 (see Safety Standards). they can throw off slag.
 Properly install and ground this equipment according to its  Wear approved safety glasses with side shields even under your
Owner’s Manual and national, state, and local codes. welding helmet.

OM-225 590 Page 1

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

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

OM-225 590 Page 2

1-3. Engine Hazards

BATTERY EXPLOSION can injure. EXHAUST SPARKS can cause fire.

 Always wear a face shield, rubber gloves, and  Do not let engine exhaust sparks cause fire.
protective clothing when working on a battery.  Use approved engine exhaust spark arrestor in
 Stop engine before disconnecting or connect- required areas — see applicable codes.
ing battery cables, battery charging cables (if
applicable), or servicing battery. HOT PARTS can burn.
 Do not allow tools to cause sparks when working on a battery.
 Do not touch hot parts bare handed.
 Do not use welder to charge batteries or jump start vehicles un-
 Allow cooling period before working on equip-
less the unit has a battery charging feature designed for this pur-
ment.
pose.
 To handle hot parts, use proper tools and/or
 Observe correct polarity (+ and −) on batteries. wear heavy, insulated welding gloves and
 Disconnect negative (−) cable first and connect it last. clothing to prevent burns.
 Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during STEAM AND HOT COOLANT can burn.
normal operation and when being charged.
 If possible, check coolant level when engine is
 Follow battery manufacturer’s instructions when working on or cold to avoid scalding.
near a battery.
 Always check coolant level at overflow tank, if
BATTERY CHARGING OUTPUT can injure. present on unit, instead of radiator (unless told
(Battery charging feature not present on all models.) otherwise in maintenance section or engine
 Have only qualified persons do battery charging work. manual).
 If the engine is warm, checking is needed, and there is no over-
 Charge lead-acid batteries only. Do not use battery charger to
flow tank, follow the next two statements.
supply power to an extra-low-voltage electrical system or to
charge dry cell batteries.  Wear safety glasses and gloves and put a rag over radiator cap.
 Do not charge a frozen battery.  Turn cap slightly and let pressure escape slowly before
 Do not use damaged charging cables. completely removing cap.

 Do not charge a battery that has loose terminals or one showing Using a generator indoors CAN KILL
damage such as a cracked case or cover. YOU IN MINUTES.
 Before charging battery, select correct charger voltage to match
battery voltage.  Generator exhaust contains carbon monoxide.
 Set battery charging controls to the Off position before connect- This is a poison you cannot see or smell.
ing to battery. Do not allow battery charging clips to touch each  NEVER use inside a home or garage, EVEN IF
other. doors and windows are open.
 Keep charging cables away from vehicle hood, door, or moving  Only use OUTSIDE and far away from windows, doors, and
parts. vents.

FUEL can cause fire or explosion. BATTERY ACID can BURN SKIN and EYES.

 Stop engine and let it cool off before checking or  Do not tip battery.
adding fuel.  Replace damaged battery.
 Do not add fuel while smoking or if unit is near  Flush eyes and skin immediately with water.
any sparks or open flames.
ENGINE HEAT can cause fire.
 Do not overfill tank — allow room for fuel to expand.
 Do not spill fuel. If fuel is spilled, clean up before starting engine.  Do not locate unit on, over, or near combustible
 Dispose of rags in a fireproof container. surfaces or flammables.
 Always keep nozzle in contact with tank when fueling.  Keep exhaust and exhaust pipes way from
flammables.
MOVING PARTS can injure.
 Keep away from moving parts such as fans,
belts, and rotors.
 Keep all doors, panels, covers, and guards
closed and securely in place.
 Stop engine before installing or connecting unit.
 Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
 To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
 Keep hands, hair, loose clothing, and tools away from moving
parts.
 Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
 Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
 Block flywheel so that it will not turn while working on generator
components.

OM-225 590 Page 3

 1-4. Hydraulic Hazards
 HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics
HYDRAULIC EQUIPMENT can injure near sparks or flames; do not smoke near hydraulic fluid.
or kill.
 Reinstall doors, panels, covers, or guards when servicing is
 Incorrect installation or operation of this unit finished and before starting unit.
could result in equipment failure and personal
injury. Only qualified persons should install, op-  If ANY fluid is injected into the skin, it must be surgically removed
erate, and service this unit according to its within a few hours by a doctor familiar with this type of injury or gan-
Owner’s Manual, industry standards, and na- grene may result.
tional, state, and local codes.
 Do not exceed the rated output or capacity of the hydraulic pump MOVING PARTS can injure.
or any equipment in the hydraulic system. Design hydraulic sys-
tem so failure of any hydraulic component will not put people or  Keep away from moving parts such as fans,
property at risk. belts and rotors.
 Before working on hydraulic system, turn off and lockout/tagout  Keep all doors, panels, covers, and guards
unit, release pressure, and be sure hydraulic pressure cannot be closed and securely in place.
accidentally applied.
 Do not work on hydraulic system with unit running unless you are  Keep hands, hair, loose clothing, and tools away from moving
a qualified person and following the manufacturer’s instructions. parts.
 Do not modify or alter hydraulic pump or manufacturer-supplied  Before working on hydraulic system, turn off and lockout/tagout
equipment. Do not disconnect, disable, or override any safety unit, release pressure, and be sure hydraulic pressure cannot be
equipment in the hydraulic system. accidentally applied.
 Use only components/accessories approved by the manufac-  Have only qualified people remove guards or covers for maint-
turer. enance and troubleshooting as necessary.
 Keep away from potential pinch points or crush points created by  Reinstall doors, panels, covers, or guards when servicing is
equipment connected to the hydraulic system. finished and before starting engine.
 Do not work under or around any equipment that is supported
only by hydraulic pressure. Properly support equipment by
mechanical means. HOT PARTS AND FLUID can burn.

 Do not touch hot parts bare handed or allow hot

fluid to contact skin.
 Allow cooling period before working on equip-
ment.
HYDRAULIC FLUID can injure or kill.
 To handle hot parts, use proper tools and/or wear heavy, insu-
 Before working on hydraulic system, turn off and lated welding gloves and clothing to prevent burns.
lockout/tagout unit, release pressure, and be sure
hydraulic pressure cannot be accidentally applied.
 Relieve pressure before disconnecting or con-
necting hydraulic lines. READ INSTRUCTIONS.
 Check hydraulic system components and all con-  Read and follow all labels and the Owner’s
nections and hoses for damage, leaks, and wear Manual carefully before installing, operating, or
before operating unit. servicing unit. Read the safety information at
 Wear protective equipment such as safety the beginning of the manual and in each
glasses, leather gloves, heavy shirt and trousers, section.
high shoes, and a cap when working on hydraulic
 Use only genuine replacement parts from the manufacturer.
system.
 Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
 Use a piece of paper or cardboard to search for leaks−−never use codes.
bare hands. Do not use equipment if leaks are found.

1-5. Compressed Air Hazards

COMPRESSED AIR EQUIPMENT can  Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s in-
injure or kill.
structions.
 Incorrect installation or operation of this unit
could result in equipment failure and personal  Do not modify or alter compressor or manufacturer-supplied
injury. Only qualified persons should install, op- equipment. Do not disconnect, disable, or override any safety
erate, and service this unit according to its equipment in the compressed air system.
Owner’s Manual, industry standards, and na-
tional, state, and local codes.  Use only components and accessories approved by the manufac-
turer.
 Do not exceed the rated output or capacity of the compressor or
any equipment in the compressed air system. Design compressed  Keep away from potential pinch points or crush points created by
air system so failure of any component will not put people or prop- equipment connected to the compressed air system.
erty at risk.
 Before working on compressed air system, turn off and lockout/  Do not work under or around any equipment that is supported only
tagout unit, release pressure, and be sure air pressure cannot be by air pressure. Properly support equipment by mechanical
accidentally applied. means.
OM-225 590 Page 4
 HOT METAL from air arc cutting and MOVING PARTS can injure.
gouging can cause fire or explosion.
 Keep away from moving parts such as fans,
 Do not cut or gouge near flammables. belts and rotors.
 Watch for fire; keep extinguisher nearby.  Keep all doors, panels, covers, and guards
closed and securely in place.
 Keep hands, hair, loose clothing, and tools away from moving
COMPRESSED AIR can injure or kill. parts.
 Before working on compressed air system, turn off and lockout/
 Before working on compressed air system, tagout unit, release pressure, and be sure air pressure cannot be
turn off and lockout/tagout unit, release pres- accidentally applied.
sure, and be sure air pressure cannot be acci-
dentally applied.  Have only qualified people remove guards or covers for maint-
enance and troubleshooting as necessary.
 Relieve pressure before disconnecting or con-
necting air lines.  Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
 Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
 Do not direct air stream toward self or others.
 Wear protective equipment such as safety glasses, hearing pro- HOT PARTS can burn.
tection, leather gloves, heavy shirt and trousers, high shoes, and
a cap when working on compressed air system.  Do not touch hot compressor or air system
 Use soapy water or an ultrasonic detector to search for leaks−− parts.
never use bare hands. Do not use equipment if leaks are found.  Allow cooling period before working on equip-
 Reinstall doors, panels, covers, or guards when servicing is ment.
finished and before starting unit.  To handle hot parts, use proper tools and/or wear heavy, insu-
 If ANY air is injected into the skin or body seek medical help im- lated welding gloves and clothing to prevent burns.
mediately.

BREATHING COMPRESSED AIR can in-

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

1-6. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. OVERHEATING can damage motors.

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

OM-225 590 Page 5

 WELDING WIRE can injure. H.F. RADIATION can cause interference.
 Do not press gun trigger until instructed to do  High-frequency (H.F.) can interfere with radio
so. navigation, safety services, computers, and
 Do not point gun toward any part of the body, communications equipment.
other people, or any metal when threading  Have only qualified persons familiar with
welding wire. electronic equipment perform this installation.
 The user is responsible for having a qualified electrician
OVERUSE can cause OVERHEATING. promptly correct any interference problem resulting from the
installation.
 Allow cooling period; follow rated duty cycle.  If notified by the FCC about interference, stop using the
 Reduce current or reduce duty cycle before equipment at once.
starting to weld again.  Have the installation regularly checked and maintained.
 Do not block or filter airflow to unit.  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.
STATIC (ESD) can damage PC boards.
 Put on grounded wrist strap BEFORE handling
boards or parts.
 Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
TILTING OF TRAILER can injure.
 Electromagnetic energy can interfere with
 Use tongue jack or blocks to support weight. sensitive electronic equipment such as micro-
 Properly install welding generator onto trailer processors, computers, and computer-driven
according to instructions supplied with trailer. equipment such as robots.
 Be sure all equipment in the welding area is
electromagnetically compatible.
READ INSTRUCTIONS.  To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
 Read and follow all labels and the Owner’s  Locate welding operation 100 meters from any sensitive elec-
Manual carefully before installing, operating, or tronic equipment.
servicing unit. Read the safety information at
 Be sure this welding machine is installed and grounded
the beginning of the manual and in each
according to this manual.
section.
 If interference still occurs, the user must take extra measures
 Use only genuine replacement parts from the manufacturer.
such as moving the welding machine, using shielded cables,
 Perform maintenance and service according to the Owner’s using line filters, or shielding the work area.
Manuals, industry standards, and national, state, and local
codes.

1-7. California Proposition 65 Warnings

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

OM-225 590 Page 6

1-8. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
from Global Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org).
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, from National Fire Protection Association,
and Cutting, American Welding Society Standard AWS F4.1, from Glob- Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
al Engineering Documents (phone: 1-877-413-5184, website: For Standards about hydraulic systems, contact the National Fluid
www.global.ihs.com). Power Association, Publications Department, 3333 North Mayfair
National Electrical Code, NFPA Standard 70, from National Fire Protec- Road, Suite 211, Milwaukee, WI 53222-3219 (phone: (414) 778-3344,
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: website: www.nfpa.com).
www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Indus-
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
from Compressed Gas Association, 4221 Walney Road, 5th Floor, and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
Safety in Welding, Cutting, and Allied Processes, CSA Standard (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
W117.2, from Canadian Standards Association, Standards Sales, 5060 phone for Region 5, Chicago, is 312-353-2220, website:
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: www.osha.gov).
800-463-6727, website: www.csa-international.org). U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
Standards Association, Standards Sales, 5060 Spectrum Way, Suite www.cpsc.gov).
100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: Applications Manual for the Revised NIOSH Lifting Equation, The Na-
www.csa-international.org). tional Institute for Occupational Safety and Health (NIOSH), 1600
Safe Practice For Occupational And Educational Eye And Face Protec- Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
tion, ANSI Standard Z87.1, from American National Standards Institute, www.cdc.gov/NIOSH).

1-9. EMF Information

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

OM-225 590 Page 7

 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
fre_rom_2009−10

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

2-1. Signification des symboles

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

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

souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
Les symboles présentés ci-après sont utilisés tout au long du à souder manuel (électrode enrobée) DC, 3) un poste à souder
présent manuel pour attirer votre attention et identifier les ris- manuel AC avec tension à vide réduite. Dans la plupart des cas, un
ques de danger. Lorsque vous voyez un symbole, soyez poste courant continu de type CV est recommandé. Et, ne pas tra-
vigilant et suivez les directives mentionnées afin d’éviter tout vailler seul!
danger. Les consignes de sécurité présentées ci-après ne  Couper l’alimentation ou arrêter le moteur avant de procéder à
font que résumer l’information contenue dans les normes de l’installation, à la réparation ou à l’entretien de l’appareil.
sécurité énumérées à la section 2-8. Veuillez lire et respecter Déverrouiller l’alimentation selon la norme OSHA 29 CFR
toutes ces normes de sécurité. 1910.147 (voir normes de sécurité).
 Installer et mettre à la terre correctement cet appareil conformé-
L’installation, l’utilisation, l’entretien et les réparations ne ment à son manuel d’utilisation et aux codes nationaux,
doivent être confiés qu’à des personnes qualifiées. provinciaux et municipaux.
 Toujours vérifier la terre du cordon d’alimentation − Vérifier et
Au cours de l’utilisation, tenir toute personne à l’écart et plus s’assurer que le fil de terre du cordon d’alimentation est bien
particulièrement les enfants. raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
 En effectuant les raccordements d’entrée fixer d’abord le conduc-
UN CHOC ÉLECTRIQUE peut tuer. teur de mise à la terre approprié et contre-vérifier les connexions.
 Les câbles doivent être exempts d’humidité, d’huile et de graisse;
Un simple contact avec des pièces électriques peut protégez−les contre les étincelles et les pièces métalliques chau-
provoquer une électrocution ou des blessures gra- des.
ves. L’électrode et le circuit de soudage sont sous  Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est
tension dès que l’appareil est sur ON. Le circuit pas endommagé ou dénudé − remplacer le cordon immédiatement
d’entrée et les circuits internes de l’appareil sont s’il est endommagé − un câble dénudé peut provoquer une électro-
également sous tension à ce moment-là. En soudage cution.
semi-automatique ou automatique, le fil, le dévidoir, le  Mettre l’appareil hors tension quand on ne l’utilise pas.
logement des galets d’entraînement et les pièces  Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
métalliques en contact avec le fil de soudage sont sante ou mal épissés.
sous tension. Des matériels mal installés ou mal mis  Ne pas enrouler les câbles autour du corps.
à la terre présentent un danger.  Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
 Ne jamais toucher les pièces électriques sous tension. câble de retour.
 Porter des gants et des vêtements de protection secs ne compor-  Ne pas toucher l’électrode quand on est en contact avec la pièce,
tant pas de trous. la terre ou une électrode provenant d’une autre machine.
 S’isoler de la pièce et de la terre au moyen de tapis ou d’autres  Ne pas toucher des porte électrodes connectés à deux machines
moyens isolants suffisamment grands pour empêcher le contact en même temps à cause de la présence d’une tension à vide dou-
physique éventuel avec la pièce ou la terre. blée.
 Ne pas se servir de source électrique à courant électrique dans les  N’utiliser qu’un matériel en bon état. Réparer ou remplacer
zones humides, dans les endroits confinés ou là où on risque de sur-le-champ les pièces endommagées. Entretenir l’appareil
tomber. conformément à ce manuel.
 Porter un harnais de sécurité quand on travaille en hauteur.
 Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.  Maintenir solidement en place tous les panneaux et capots.
 Fixer le câble de retour de façon à obtenir un bon contact métal-
 Si l’utilisation d’une source électrique à courant électrique s’avère métal avec la pièce à souder ou la table de travail, le plus près pos-
nécessaire, se servir de la fonction de télécommande si l’appareil sible de la soudure.
en est équipé.
 Isoler la pince de masse quand pas mis à la pièce pour éviter le
 Des précautions de sécurité supplémentaires sont requises dans contact avec tout objet métallique.
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures mé-
Il reste une TENSION DC NON NÉGLIGEABLE dans les
talliques au sol, grillages et échafaudages; dans des positions sources de soudage onduleur UNE FOIS le moteur coupé.
assises, à genoux et allongées; ou quand il y a un risque important  Couper l’alimentation du poste et décharger les condensateurs
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser d’entrée comme indiqué dans la Section Maintenance avant de
les appareils suivants dans l’ordre de préférence: 1) un poste à toucher des composants.
OM-225 590 Page 8
 LES PIÈCES CHAUDES peuvent  Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
provoquer des brûlures. et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
 Ne pas toucher à mains nues les parties chau- et Z87.1 énuméré dans les normes de sécurité).
des.  Porter des lunettes de sécurité avec écrans latéraux même sous
 Prévoir une période de refroidissement avant votre casque.
de travailler à l’équipement.  Avoir recours à des écrans protecteurs ou à des rideaux pour
 Ne pas toucher aux pièces chaudes, utiliser les outils recomman- protéger les autres contre les rayonnements les éblouissements
dés et porter des gants de soudage et des vêtements épais pour et les étincelles ; prévenir toute personne sur les lieux de ne pas
éviter les brûlures. regarder l’arc.
 Porter des vêtements confectionnés avec des matières résistan-
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
DES PIECES DE METAL ou DES LE SOUDAGE peut provoquer un
SALETES peuvent provoquer incendie ou une explosion.
des blessures dans les yeux.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
 Le soudage, l’écaillement, le passage de la pièce à la brosse en
provoquer leur éclatement. Des étincelles peuvent
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des être projetées de l’arc de soudure. La projection d’étincelles, des
soudures, elles risquent de projeter du laitier. pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
 Porter des lunettes de sécurité avec écrans latéraux ou un écran des objets métalliques peut provoquer des étincelles, une explosion,
facial. un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
LES FUMÉES ET LES GAZ peu-
 Déplacer toutes les substances inflammables à une distance de
vent être dangereux. 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
Le soudage génère des fumées et des gaz. Leur soigneusement avec des protections homologués.
inhalation peut être dangereux pour votre santé.  Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
 Eloigner votre tête des fumées. Ne pas respirer les fumées.  Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
 À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.  Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
 Si la ventilation est médiocre, porter un respirateur anti-vapeurs fissures et des ouvertures.
approuvé.
 Surveiller tout déclenchement d’incendie et tenir un extincteur à
 Lire et comprendre les spécifications de sécurité des matériaux proximité.
(MSDS) et les instructions du fabricant concernant les métaux, les  Le soudage effectué sur un plafond, plancher, paroi ou séparation
consommables, les revêtements, les nettoyants et les dégraisseurs. peut déclencher un incendie de l’autre côté.
 Travailler dans un espace fermé seulement s’il est bien ventilé ou  Ne pas effectuer le soudage sur des conteneurs fermés tels que
en portant un respirateur à alimentation d’air. Demander toujours à des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
un surveillant dûment formé de se tenir à proximité. Des fumées et préparés correctement conformément à AWS F4.1 (voir les nor-
des gaz de soudage peuvent déplacer l’air et abaisser le niveau mes de sécurité).
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.  Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
peurs inflammables (vapeur d’essence, par exemple).
 Ne pas souder dans des endroits situés à proximité d’opérations
 Brancher le câble de masse sur la pièce le plus près possible de la
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
zone de soudage pour éviter le transport du courant sur une
les rayons de l’arc peuvent réagir en présence de vapeurs et for-
longue distance par des chemins inconnus éventuels en provo-
mer des gaz hautement toxiques et irritants.
quant des risques d’électrocution, d’étincelles et d’incendie.
 Ne pas souder des métaux munis d’un revêtement, tels que l’acier  Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
galvanisé, plaqué en plomb ou au cadmium à moins que le revête- lées.
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les  En cas de non utilisation, enlever la baguette d’électrode du porte-
revêtements et tous les métaux renfermant ces éléments peuvent électrode ou couper le fil à la pointe de contact.
dégager des fumées toxiques en cas de soudage.  Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
LES ACCUMULATIONS DE GAZ revers, des chaussures hautes et un couvre chef.
risquent de provoquer des blessures  Avant de souder, retirer toute substance combustible de vos po-
ou même la mort. ches telles qu’un allumeur au butane ou des allumettes.
 Fermer l’alimentation du gaz protecteur en cas  Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-
de non utilisation. ce d’étincelles incandescentes ni de flammes.
 Veiller toujours à bien aérer les espaces confinés ou se servir  Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
d’un respirateur d’adduction d’air homologué. Ne pas augmenter leur puissance; ne pas les ponter.
 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
LES RAYONS DE L’ARC peuvent extincteur à proximité.
provoquer des brûlures dans les
yeux et sur la peau. LE BRUIT peut affecter l’ouïe.
Le rayonnement de l’arc du procédé de soudage
Le bruit des processus et des équipements peut
génère des rayons visibles et invisibles intenses
affecter l’ouïe.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le  Porter des protections approuvés pour les
soudage. oreilles si le niveau sonore est trop élevé.

OM-225 590 Page 9

 Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)  Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
peuvent affecter les implants médicaux. de se renverser.
 Les porteurs de stimulateurs cardiaques et  Tenir les bouteilles éloignées des circuits de soudage ou autres
autres implants médicaux doivent rester à circuits électriques.
distance.  Ne jamais placer une torche de soudage sur une bouteille à gaz.
 Les porteurs d’implants médicaux doivent consulter leur  Une électrode de soudage ne doit jamais entrer en contact avec
médecin et le fabricant du dispositif avant de s’approcher de la une bouteille.
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage  Ne jamais souder une bouteille pressurisée − risque d’explosion.
par induction.  Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Si des BOUTEILLES sont endomma-  Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
gées, elles pourront exploser. bouteille.
Des bouteilles de gaz protecteur contiennent du gaz  Maintenir le chapeau de protection sur la soupape, sauf en cas
sous haute pression. Si une bouteille est endomma- d’utilisation ou de branchement de la bouteille.
gée, elle peut exploser. Du fait que les bouteilles de gaz font  Utiliser les équipements corrects, les bonnes procédures et suffi-
normalement partie du procédé de soudage, les manipuler avec samment de personnes pour soulever et déplacer les bouteilles.
précaution.
 Lire et suivre les instructions sur les bouteilles de gaz comprimé,
 Protéger les bouteilles de gaz comprimé d’une chaleur excessive, l’équipement connexe et le dépliant P-1 de la CGA (Compressed
des chocs mécaniques, des dommages physiques, du laitier, des Gas Association) mentionné dans les principales normes de sécu-
flammes ouvertes, des étincelles et des arcs. rité.

2-3. Dangers existant en relation avec le moteur

 Ranger les câbles de charge à distance du capot, des portes et
L’EXPLOSION DE LA BATTERIE des pièces mobiles du véhicule.
peut provoquer des blessures.
 Toujours porter une protection faciale, des LE CARBURANT MOTEUR peut pro-
gants en caoutchouc et vêtements de protec- voquer un incendie ou une explosion.
tion lors d’une intervention sur la batterie.
 Arrêter le moteur avant de vérifier le niveau de
 Arrêter le moteur avant de débrancher ou de brancher des câbles carburant ou de faire le plein.
de batterie, des câbles de chargeur de batterie (le cas échéant) ou
 Ne pas faire le plein en fumant ou proche d’une source d’étincel-
de batterie d’entretien.
les ou d’une flamme nue.
 Eviter de provoquer des étincelles avec les outils en travaillant sur  Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
la batterie. pour son expansion.
 Ne pas utiliser l’appareil de soudage pour charger des batteries ou  Faire attention de ne pas renverser de carburant. Nettoyer tout
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf carburant renversé avant de faire démarrer le moteur.
si l’appareil dispose d’une fonctionnalité de charge de batterie
destinée à cet usage.  Jeter les chiffons dans un récipient ignifuge.
 Toujours garder le pistolet en contact avec le réservoir lors du
 Observer la polarité correcte (+ et −) sur les batteries.
remplissage.
 Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
 Les sources d’étincelles, flammes nues, cigarettes et autres Les PIÈCES MOBILES peuvent causer
sources d’inflammation doivent être maintenues à l’écart des des blessures.
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.
 S’abstenir de toucher des parties mobiles telles
 Respecter les consignes du fabricant de la batterie pour que des ventilateurs, courroies et rotors.
travailler sur une batterie ou à proximité.
 Maintenir fermés et verrouillés les portes, panneaux,
Le COURANT DE CHARGE DE BATTERIE peut recouvrements et dispositifs de protection.
provoquer des blessures (la fonctionnalité de charge de
batterie n’est pas disponible sur tous les modèles).  Arrêter le moteur avant d’installer ou brancher l’appareil.
 Les opérations de charge de batterie ne doivent être effectuées  Lorsque cela est nécessaire pour des travaux d entretien et de
que par des personnes qualifiées. dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
 Ne charger que des batteries plomb−acide. Ne pas utiliser le
chargeur de batterie pour alimenter un autre circuit électrique  Pour empêcher tout démarrage accidentel pendant les travaux
basse tension ou pour charger des batteries sèches. d’entretien, débrancher le câble négatif (−) de batterie de la borne.
 Ne pas charger une batterie gelée.  Ne pas approcher les mains, cheveux, vêtements lâches et outils
 Ne pas utiliser de câbles de charge endommagés. des organes mobiles.
 Ne pas charger une batterie dont les bornes sont desserrées ou  Remettre en place les portes, panneaux, recouvrements ou
présentant une détérioration comme par exemple un boîtier ou un dispositifs de protection à la fin des travaux d’entretien et avant de
couvercle fissuré. mettre le moteur en marche.
 Avant de charger une batterie, sélectionner la tension de charge
correspondant à la tension de la batterie.  Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
mise en route accidentelle du moteur.
 Régler les commandes de charge de batterie sur la position d’arrêt
avant de brancher la batterie. Veiller à ce que les pinces de charge  Bloquer le volant moteur pour éviter sa rotation lors d’une
ne se touchent pas. intervention sur le générateur.
OM-225 590 Page 10
  Mettre des lunettes de sécurité et des gants, placer un torchon sur
LES ÉTINCELLES À L’ÉCHAPPEMENT le bouchon du radiateur.
peuvent provoquer un incendie.
 Dévisser le bouchon légèrement et laisser la vapeur s’échapper
 Empêcher les étincelles d’échappement du avant d’enlever le bouchon.
moteur de provoquer un incendie.
 Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur. L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.  Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisi-
 Ne pas toucher des parties chaudes à mains ble et inodore.
nues.
 JAMAIS utiliser dans une maison ou garage,
 Prévoir une période de refroidissement avant de même avec les portes et fenêtres ouvertes.
travailler à l’équipement.
 Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
 Ne pas toucher aux pièces chaudes, utiliser les outils recomman- bouches aération.
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
L’ACIDE DE LA BATTERIE peut pro-
LA VAPEUR ET LE LIQUIDE DE voquer des brûlures dans les YEUX et
REFROIDISSEMENT CHAUD peuvent sur la PEAU.
provoquer des brûlures.  Ne pas renverser la batterie.
 Il est préférable de vérifier le liquide de refroi-  Remplacer une batterie endommagée.
dissement une fois le moteur refroidi pour éviter  Rincer immédiatement les yeux et la peau à l’eau.
de se brûler.
LA CHALEUR DU MOTEUR peut pro-
 Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si pré- voquer un incendie.
cisé autrement dans la section maintenance du manuel du  Ne pas placer l’appareil sur, au-dessus ou à
moteur). proximité de surfaces inflammables.
 Si le moteur est chaud et que le liquide doit être vérifié, opérer com-  Tenir à distance les produits inflammables de l’échappement.
me suivant.

2-4. Dangers liés à l’hydraulique

Les ÉQUIPEMENTS HYDRAULIQUES  Ne pas intervenir sous ou autour d’un équipement qui n’est
peuvent provoquer des blessures ou soutenu que par la pression hydraulique. Soutenir l’équipement
même la mort. de façon appropriée par un moyen mécanique.

 Une installation ou une utilisation incorrecte

de cet appareil pourrait conduire à des dégâts Le LIQUIDE HYDRAULIQUE risque de
matériels ou corporels. Seul un personnel provoquer des blessures ou même la mort.
qualifié est autorisé à installer, faire fonctionner
et réparer cet appareil conformément à son  Avant d’intervenir sur le circuit hydraulique,
manuel d’utilisation, aux normes industrielles couper l’alimentation électrique, verrouiller
et aux codes nationaux, d’état ou locaux. et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit hydraulique ne peut
être remis sous pression par inadvertance.
 Ne pas dépasser le débit nominal ou la capacité de la pompe  Détendre la pression avant de débrancher ou
hydraulique ou de tout équipement du circuit hydraulique. de brancher des canalisations hydrauliques.
Concevoir le circuit hydraulique de telle sorte que la défaillance  Avant d’utiliser l’appareil, contrôler
d’un composant hydraulique ne risque pas de provoquer les composants du circuit hydraulique,
un accident matériel ou corporel. les branchements et les flexibles en recherchant
tout signe de détérioration, de fuite et d’usure.
 Avant d’intervenir sur le circuit hydraulique, couper l’alimentation
électrique, verrouiller et étiqueter l’appareil, détendre la pression  Pour intervenir sur un circuit hydraulique, porter un équipement
et s’assurer que le circuit hydraulique ne peut être remis sous de protection tel que des lunettes de sécurité, des gants de cuir,
pression par inadvertance. une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
 Ne pas intervenir sur le circuit hydraulique lorsque l’appareil
fonctionne. Seul un personnel qualifié et appliquant les consignes  Pour rechercher des fuites, utiliser un morceau de papier ou
du fabricant est autorisé le faire. de carton, jamais les mains nues. En cas de détection de fuite,
ne pas utiliser l’équipement.
 Ne pas modifier ou altérer la pompe hydraulique ou
les équipements fournis par le fabricant. Ne pas débrancher,  Le LIQUIDE HYDRAULIQUE est INFLAMMABLE. Ne pas
désactiver ou neutraliser les équipements de sécurité du circuit intervenir sur des composants hydrauliques à proximité
hydraulique. d’étincelles ou de flammes; ne pas fumer à proximité de liquide
hydraulique.
 Utiliser uniquement des composants et accessoires homologués  Remettre les portes, panneaux, recouvrements ou dispositifs
par le fabricant. de protection quand l’entretien est terminé et avant de mettre
 Se tenir à l’écart de tout point présentant un danger de pincement en marche l’appareil.
ou d’écrasement créé par l’équipement raccordé au circuit  En cas de pénétration d’un QUELCONQUE liquide dans la peau,
hydraulique. celui−ci doit être retiré chirurgicalement sous quelques heures par
OM-225 590 Page 11
 un médecin familiarisé avec ce type de blessure, faute de quoi
la gangrène pourrait apparaître. LES PIÈCES ET LIQUIDES CHAUDS
peuvent provoquer des brûlures.
Les PIÈCES MOBILES peuvent causer  Ne pas toucher les pièces chaudes à main nue
des blessures. ni laisser des liquides chauds entrer en contact
avec la peau.
 S’abstenir de toucher des parties mobiles telles
 Prévoir une période de refroidissement avant d’intervenir
que des ventilateurs, courroies et rotors.
sur l’équipement.
 Maintenir fermés et verrouillés les portes,
 Ne pas toucher aux pièces chaudes, utiliser les outils
panneaux, recouvrements et dispositifs
recommandés et porter des gants de soudage et des vêtements
de protection.
épais pour éviter les brûlures.
 Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
LIRE LES INSTRUCTIONS.
 Avant d’intervenir sur le circuit hydraulique, couper l’alimentation
électrique, verrouiller et étiqueter l’appareil, détendre la pression  Lire et appliquer les instructions sur les
et s’assurer que le circuit hydraulique ne peut être remis sous étiquettes et le Mode d’emploi avant
pression par inadvertance. l’installation, l’utilisation ou l’entretien de
 Demander seulement à un personnel qualifié d’enlever l’appareil. Lire les informations de sécurité au
les dispositifs de sécurité ou les recouvrements pour effectuer, début du manuel et dans chaque section.
s’il y a lieu, des travaux d’entretien et de dépannage.  N’utiliser que les pièces de rechange recommandées par le
 Remettre en place les portes, panneaux, recouvrements ou constructeur.
dispositifs de protection à la fin des travaux d’entretien et avant  Effectuer l’entretien en respectant les manuels d’utilisation,
de mettre le moteur en marche. les normes industrielles et les codes nationaux, d’état et locaux.

2-5. Dangers liés à l’air comprimé

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

L’INHALATION D’AIR COMPRIMÉ risque

MÉTAL CHAUD provenant du décou- de provoquer des blessures ou même
page ou du gougeage à l’arc risque de la mort.
provoquer un incendie ou une explo-
sion.  Ne pas inhaler d’air comprimé.
 Utiliser l’air comprimé uniquement pour
 Ne pas découper ou gouger à proximité de découper ou gouger ainsi que pour l’outillage
produits inflammables. pneumatique.
 Attention aux risques d’incendie: tenir un extincteur à proximité.

OM-225 590 Page 12

  Remettre en place les portes, panneaux, recouvrements ou
Une PRESSION D’AIR RÉSIDUELLE dispositifs de protection à la fin des travaux d’entretien et avant
ET DES FLEXIBLES QUI FOUETTENT de mettre le moteur en marche.
risquent de provoquer des blessures.

 Détendre la pression pneumatique des outils et

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

2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU LES ÉTINCELLES PROJETÉES
D’EXPLOSION. peuvent provoquer des blessures.
 Ne pas placer l’appareil sur, au-dessus ou  Porter un écran facial pour protéger le visage et
à proximité de surfaces inflammables. les yeux.
 Ne pas installer l’appareil à proximité de pro-  Affûter l’électrode au tungstène uniquement à
duits inflammables. la meuleuse dotée de protecteurs. Cette ma-
 Ne pas surcharger l’installation électrique − s’assurer que l’ali- nœuvre est à exécuter dans un endroit sûr lors-
mentation est correctement dimensionnée et protégée avant de que l’on porte l’équipement homologué de pro-
mettre l’appareil en service. tection du visage, des mains et du corps.
 Les étincelles risquent de causer un incendie − éloigner toute
LA CHUTE DE L’ÉQUIPEMENT substance inflammable.
peut provoquer des blessures.
 Utiliser l’anneau de levage pour lever l’appareil
et les accessoires correctement installées
Les PIÈCES MOBILES peuvent
seuls, PAS les bouteilles de gaz. Ne pas dé-
passer le poids nominal maximal de l’œilleton
causer des blessures.
(voir les spécifications).  Ne pas s’approcher des organes mobiles.
 Utiliser un équipement de levage de capacité suffisante pour  Ne pas s’approcher des points de coincement
lever l’appareil. tels que des rouleaux de commande.
 En utilisant des fourches de levage pour déplacer l’unité, s’assu-
rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil. LES FILS DE SOUDAGE peuvent
 Tenir l’équipement (câbles et cordons) à distance des véhicules provoquer des blessures.
mobiles lors de toute opération en hauteur.  Ne pas appuyer sur la gâchette avant d’en
 Suivre les consignes du Manuel des applications pour l’équation avoir reçu l’instruction.
de levage NIOSH révisée (Publication Nº94−110) lors du levage  Ne pas diriger le pistolet vers soi, d’autres per-
manuelle de pièces ou équipements lourds. sonnes ou toute pièce mécanique en enga-
geant le fil de soudage.
LE SURCHAUFFEMENT peut
endommager le moteur électrique. L’EMPLOI EXCESSIF peut
 Arrêter ou déconnecter l’équipement avant de SURCHAUFFER L’ÉQUIPEMENT.
démarrer ou d’arrêter le moteur.
 Laisser l’équipement refroidir ; respecter le fac-
 Ne pas laisser tourner le moteur trop lentement sous risque d’en- teur de marche nominal.
dommager le moteur électrique à cause d’une tension et d’une fré-
quence trop faibles.  Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
 Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,
s’il y a lieu.  Ne pas obstruer les passages d’air du poste.

OM-225 590 Page 13

  Demander seulement à des personnes qualifiées familiarisées
LES CHARGES ÉLECTROSTATI- avec des équipements électroniques de faire fonctionner l’installa-
QUES peuvent endommager les tion.
circuits imprimés.  L’utilisateur est tenu de faire corriger rapidement par un électricien
 Établir la connexion avec la barrette de terre qualifié les interférences résultant de l’installation.
avant de manipuler des cartes ou des pièces.  Si le FCC signale des interférences, arrêter immédiatement l’ap-
 Utiliser des pochettes et des boîtes antistatiques pour stocker, pareil.
déplacer ou expédier des cartes de circuits imprimes.  Effectuer régulièrement le contrôle et l’entretien de l’installation.
UNE REMORQUE QUI BASCULE peut  Maintenir soigneusement fermés les portes et les panneaux des
provoquer des blessures. sources de haute fréquence, maintenir les éclateurs à une distan-
ce correcte et utiliser une terre et un blindage pour réduire les
 Utiliser les supports de la remorque ou des
interférences éventuelles.
blocs pour soutenir le poids.
 Installer convenablement le poste sur la remor-
que comme indiqué dans le manuel s’y rappor- LE SOUDAGE À L’ARC risque de
tant. provoquer des interférences.
LIRE LES INSTRUCTIONS.  L’énergie électromagnétique risque de provo-
quer des interférences pour l’équipement élec-
 Lire et appliquer les instructions sur les tronique sensible tel que les ordinateurs et
étiquettes et le Mode d’emploi avant l’équipement commandé par ordinateur tel que
l’installation, l’utilisation ou l’entretien de les robots.
l’appareil. Lire les informations de sécurité au  Veiller à ce que tout l’équipement de la zone de soudage soit
début du manuel et dans chaque section. compatible électromagnétiquement.
 N’utiliser que les pièces de rechange recommandées par le  Pour réduire la possibilité d’interférence, maintenir les câbles de
constructeur. soudage aussi courts que possible, les grouper, et les poser
 Effectuer l’entretien en respectant les manuels d’utilisation, aussi bas que possible (ex. par terre).
les normes industrielles et les codes nationaux, d’état et locaux.  Veiller à souder à une distance de 100 mètres de tout équipe-
ment électronique sensible.
LE RAYONNEMENT HAUTE FRÉ-  Veiller à ce que ce poste de soudage soit posé et mis à la terre
QUENCE (H.F.) risque de provoquer conformément à ce mode d’emploi.
des interférences.  En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
 Le rayonnement haute fréquence (H.F.) peut mentaires telles que le déplacement du poste, l’utilisation de câ-
provoquer des interférences avec les équipe- bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
ments de radio−navigation et de communica- teurs dans la zone de travail.
tion, les services de sécurité et les ordinateurs.

2-7. Proposition californienne 65 Avertissements

Pour les moteurs à essence :
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal- Les gaz d’échappement des moteurs contiennent des pro-
formations congénitales et, dans certains cas, des cancers. duits chimiques dont l’État de Californie reconnaît qu’ils
(Code de santé et de sécurité de Californie, chapitre 25249.5 provoquent des cancers et des malformations congénitales
et suivants) ou autres problèmes de procréation.

Pour les moteurs diesel :

Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi-
ques dont l’État de Californie reconnaît qu’ils provoquent des Les gaz d’échappement des moteurs diesel et certains de
cancers et des malformations congénitales ou autres leurs composants sont reconnus par l’État de Californie com-
problèmes de procréation. Se laver les mains après manipu- me provoquant des cancers et des malformations
lation. congénitales ou autres problèmes de procréation.

2-8. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
from Global Engineering Documents (phone: 1-877-413-5184, website: Standards Association, Standards Sales, 5060 Spectrum Way, Suite
www.global.ihs.com). 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
www.csa-international.org).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob- Safe Practice For Occupational And Educational Eye And Face Protec-
al Engineering Documents (phone: 1-877-413-5184, website: tion, ANSI Standard Z87.1, from American National Standards Institute,
www.global.ihs.com). 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
site: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protec- Standard for Fire Prevention During Welding, Cutting, and Other Hot
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: Work, NFPA Standard 51B, from National Fire Protection Association,
www.nfpa.org and www. sparky.org). Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, For Standards about hydraulic systems, contact the National Fluid
from Compressed Gas Association, 4221 Walney Road, 5th Floor, Power Association, Publications Department, 3333 North Mayfair
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Road, Suite 211, Milwaukee, WI 53222-3219 (phone: (414) 778-3344,
website: www.nfpa.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060 OSHA, Occupational Safety and Health Standards for General Indus-
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
800-463-6727, website: www.csa-international.org). and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
OM-225 590 Page 14
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— www.cpsc.gov).
phone for Region 5, Chicago, is 312-353-2220, website: Applications Manual for the Revised NIOSH Lifting Equation, The Na-
www.osha.gov). tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
U.S. Consumer Product Safety Commission (CPSC), 4330 East West www.cdc.gov/NIOSH).

2-9. Informations relatives aux CEM

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

OM-225 590 Page 15

 SECTION 3 − DEFINITIONS

3-1. Symbols And Definitions

Stop Engine Start Engine Ether Starting Aid Engine

Do Not Switch
While Welding Battery (Engine) Circuit Protector Engine Oil
Or Under Load

Check Injectors/ Check Valve Protective Earth

Fuel
Pump Clearance (Ground)

Certified/Trained
Positive Negative Welding Arc
Mechanic

A Amperes
V Volts Panel/Local Remote

Alternating
On Temperature Output (Contactor)
Current

3
Stick (SMAW) TIG (GTAW) MIG (GMAW)
Three Phase
Welding Welding Welding

h s 1
Time Hours Seconds Single Phase

Read Operator’s
Manual

OM-225 590 Page 16

 SECTION 4 − SPECIFICATIONS
4-1. Description
This unit has two CC/CV modules with separate weld controls for applications where two welding arcs are needed. A
Welder Selector switch controls whether one or both sets of weld output terminals are active (see Section 6-2). When
the unit is operated in the dual operator mode, each welder has CC and CV weld output available for Stick, TIG, and
MIG welding. When in the single operator mode, CC weld output is available to the welder on the Welder B (right) side
only (CV not active in single operator mode).

4-2. Weld, Power, And Engine Specifications

Max.
Weld Weld Rated
Weld Weld Open- Generator Power Fuel
Stations Output Welding Engine
Mode Output Circuit Rating Capacity
Available Range Output
Voltage
550 A at 30
1 Single-Phase, Deutz
Single CC/DC 30 − 600 A 85 Volts DC, 40%
(Right Side) 4 kVA/kW, 34/17 A, D914L03i
Duty Cycle
120/240 V AC, Air-Cooled, 22.3 gal
50/60 Hz Three-Cylinder, (84.4 L)
CC/DC 15 − 300 A 85 275 A at 31
2 (4 kVA/kW Shared By 48.2 HP Diesel
Dual Volts DC, 40%
(Both Sides) All Receptacles) Engine
CV/DC 10 − 32 V 49 Duty Cycle

4-3. Dimensions, Weights, And Operating Angles

Dimensions
Height 47-5/8 in (1210 mm)
Width 31-1/4 in (794 mm) L
Depth 60-1/2 in (1537 mm) ! Do not exceed tilt angles or engine could
Engine End
A 59-1/8 in (1502 mm) be damaged or unit could tip.
! Do not move or operate unit where it
B 47-1/4 in (1200 mm)
could tip.
C 43-1/4 in (1099 mm)
D 32-3/4 in (832 mm)
E 24-15/16 in (633 mm)
F 10-1/2 in (267 mm) A
C
G 6-1/2 in (165 mm) B
D
H 2-7/8 in (73 mm)
E 17.5°
J 29-7/8 in (759 mm)
F
K 11/16 in (24 mm) 20° 17.5°
21/32 in (17 mm) Dia. G 20°
L H
16 Holes K J
Weight angles_1 8/99

2115 lb (959 kg) 158 699

Lifting Eye Weight Rating:

2161 lb (980 kg) Maximum

OM-225 590 Page 17

4-4. Fuel Consumption
The curve shows typical fuel use un-
der the combined weld loads of both
sides (Welder A and Welder B).

7.57 1.70 2.00

6.62 1.46 1.75

5.67 1.25 1.50

4.73 1.04 1.25

CC
3.78 0.83 1.00

2.84 0.62 0.75 CV

1.98 0.40 0.50

0.95 0.21 0.25

0
0 50 100 150 200 250 300 350 400 450 500 550 600
LITERS/HR.

DC WELD AMPERES AT 40% DUTY CYCLE

IMP. GAL./HR.

U.S. GAL./HR.

195 711

4-5. AC Generator Power

The ac power curve shows the gen-
erator power in amperes available
at the 120 and 240 volt receptacles.

150 300

125 250
AC VOLTS

100 200

75 150

50 100

25 50

0 0
0 5 10 15 20 25 30
AC AMPERES IN 240V MODE
0 10 20 30 40 50 60
AC AMPERES IN 120V MODE

193 018

OM-225 590 Page 18

4-6. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
NOTICE − Exceeding duty cycle
Dual Operator Mode − 40% Duty Cycle At 275 Amperes From Each Side can damage unit and void warranty.
Single Operator Mode − 40% Duty Cycle At 550 Amperes From Welder B side (Right)
If a weld module overheats, the
High Temperature light goes on and
the thermostat opens to stop weld
output to that module. Wait fifteen
minutes for module to cool. Reduce
amperage, voltage, or duty cycle
before welding.
This unit has separate duty cycle
4 Minutes Welding 6 Minutes Resting ratings for each operating mode. If
the unit is operated in the dual oper-
ator mode, the unit is rated at 40%
duty cycle. This means each side of
the unit can be operated at 275 am-
peres at 40% duty cycle.
When the unit is operated in the
single operator mode, the Welder B
side (right) is rated at 40% duty
cycle (550 A at 40% duty cycle).

Overheating

A or V
0

15
OR
Reduce Duty Cycle
Minutes
Ref. rduty1 5/95 − 194 313-A

OM-225 590 Page 19

4-7. Volt-Ampere Curves
A. CC/DC − Single Mode The volt-ampere curve shows the
minimum, medium, and maximum
100 voltage and amperage output capa-
bilities of the welding generator.
Curves of all other settings fall be-
80 tween the curves shown.
DC VOLTS

60
MIN MED MAX

40

20

0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
B. CC/DC − Dual Mode
100

80
MIN MED MAX
DC VOLTS

60

40

20

0
0 50 100 150 200 250 300 350 400 450 500
DC AMPERES
C. CV/DC Mode
100

80
DC VOLTS

60

40
MAX
MED
20
MIN
0
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
194 397 / 194 398 / 194 399

OM-225 590 Page 20

 SECTION 5 − INSTALLATION
 When facing the front panel, the Welder B controls and weld terminals are on the right and the Welder A controls and weld terminals are on the
left.

5-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on back cover of this manual.

5-2. Installing Welding Generator

! Do not move or operate unit
where it could tip.
! Do not lift unit from end.
Movement
! Always securely fasten welding
generator onto transport vehicle
or trailer and comply with all DOT
and other applicable codes.
NOTICE − Do not install unit where air
flow is restricted or engine may over-
OR heat.

 See Section 4-3 for lifting eye rating.

Location / Airflow Clearance

OR

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

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

install1 1/08 − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / 804 712

OM-225 590 Page 21

5-3. Grounding Generator To Truck Or Trailer Frame

! Always ground generator

frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
! Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
! Bed liners, shipping skids,
and some running gear insu-
late the welding generator
from the vehicle frame. Al-
ways connect a ground wire
from the generator equip-
1 2 ment grounding terminal to
bare metal on the vehicle
GND/PE frame as shown.
! If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.
1 Equipment Grounding
Terminal (On Front Panel)
3 2 Grounding Cable (Not
Supplied)
3 Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.

 Electrically bond generator

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

rot_grnd 2008-01 − 800 652-D

OM-225 590 Page 22

5-4. Activating The Dry Charge Battery (If Applicable)
! Always wear a face shield,
rubber gloves and protective
clothing when working on a
battery.
3
Remove battery from unit.
1 Vent Caps
2 2 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
1 3 Well
Fill each cell with electrolyte to
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.
4 Battery Charger
! Read and follow all instruc-
tions supplied with battery
charger.
5 5 Amperes For 30 Minutes
Charge Time
5 6 30 Amperes For 12 Minutes
4 Charge Time
Charge battery. Disconnect charg-
ing cables and install battery.

 When electrolyte is low, add

only distilled water to cells to
5A maintain proper level.

+
6

−
Tools Needed: 30 A
drybatt 12008−01 − S-0886

5-5. Connecting The Battery

! Connect (−) Cable Last.

Tools Needed:
1/2 in

Ref 225 543 / 153 654-C

OM-225 590 Page 23

5-6. Installing Exhaust Pipe
! Stop engine and let cool.
! Do not blow exhaust toward
air cleaner or air intake.

Top View

Tools Needed:
1/2 in

exh_pipe2 4/96 − 154 089-A / 154 611 / 190 377

5-7. Engine Prestart Checks

Check all fluids daily. Engine must
be cold and on a level surface.
Follow run-in procedure in engine
manual. If unburned fuel and oil col-
lect in exhaust pipe during run-in,
see Section 10.
1/2 in
(13 mm) Fuel
Full
NOTICE − Do not use gasoline.
Gasoline will damage engine.
Add diesel fuel before starting
Diesel engine the first time (see mainte-
nance label for specifications). Fill
fuel tank up to 1/2 in. (13 mm) from
top to allow room for expansion.
Open fuel shut-off valve.
Do not run out of fuel or air enters
fuel system and causes starting
problems. Use primer pump to
prime injector system (see Section
8-7).
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see main-
tenance label).

 Engine stops if oil pressure is

too low.
OFF
 To improve cold weather
FUEL ON starting:

Keep battery in good condition.

Store battery in warm area.

Use fuel formulated for cold

weather (diesel fuel can gel in
cold weather). Contact local
fuel supplier for fuel in-
formation.
Full
Use correct grade oil for cold
weather.
Ref 804 285 / 013 466

OM-225 590 Page 24

5-8. Safety Information For Connecting To Weld Output Terminals

! UNEXPECTED WELD OUTPUT can cause injury or fire.

 Both weld outputs can be live (ON) when Welder Selector switch is in Welder A/Welder B position and engine is running.
 Disconnect or insulate any unused cables.
 Know where cables are located BEFORE starting engine.
! ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical connections.
 Stop engine before making any weld output connections.
 Do not connect welding output of different polarities to the same structure.
 See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual).
 When welding on the same workpiece, all connections to the workpiece must be of the same polarity.
 Do not handle or come in contact with two live electrodes at the same time.
! ELECTRIC SHOCK can kill; TWO TIMES NORMAL OPEN-CIRCUIT VOLTS can exist between electrode holders of opposite polarity.
 Do not touch electrode holders of opposite polarity at the same time.
 Separate electrode holders of opposite polarity to prevent contact.
 Consult ANSI Z49.1 for common grounding safe practices.

OM-225 590 Page 25

5-9. Weld Output Terminals

Welder A (Left) Side Welder B (Right) Side

9 8 7
7 8 9 Tools Needed:
3/4 in.
2
1

6
3

Ref. 225 543 / 802 292-A / 803 788-B

! Stop engine. 3 Weld Output Terminal 9 CC Weld Output Terminal

! Failure to properly connect weld 4 Supplied Weld Output Terminal Nut See Sections 5-10 thru 5-15 for dual opera-
cables may cause excessive heat 5 Weld Cable Terminal tor output connections for CC and CV weld-
and start a fire, or damage your ma- 6 Copper Bar ing.
chine. Remove supplied nut from weld output ter- See Section 5-16 for single operator output
 Do not place anything between weld minal. Slide weld cable terminal onto weld connections (CC only).
cable terminal and copper bar. Make output terminal and secure with nut so that
weld cable terminal is tight against copper If unit has the Polarity switch option, the
sure that the surfaces of the weld cable Negative (−) weld output terminals are la-
terminal and copper bar are clean. bar.
beled Work receptacles and the CC weld
1 Correct Weld Cable Connection 7 Negative (−) Weld Output Terminal output terminals are labeled Electrode re-
2 Incorrect Weld Cable Connection 8 CV Weld Output Terminal ceptacles.

OM-225 590 Page 26

5-10. Making Dual Operator CC Weld Connections w/ Separate Work Cables
Tools Needed:

3/4 in

Direct Current Electrode Positive

(DCEP) connections are shown.

Welder A (Left) Side Welder B (Right) Side

Note position
of Process
Selector
switches.

2 1 2

Ref. 225 543 / 802 292-A

! Stop engine. Route cables through strain reliefs. CC terminals and electrode holder cables
2 Electrode Holder Cables to Negative (−) terminals.
NOTICE − Do not exceed machine duty
cycle. 3 Work Cables If unit has the Polarity switch option, con-
For Stick/TIG welding Direct Current Elec- nect work cables to Work receptacles and
 Use Dual Operator mode for CC and trode Positive (DCEP), connect work electrode holder cables to Electrode recep-
CV welding (see Section 6-1). cables to Negative (−) terminals and elec- tacles.
trode holder cables to CC terminals.
See Section 5-17 for proper cable size.
For Stick/TIG Direct Current Electrode  Be sure Process Selector switches
1 Strain Reliefs Negative (DCEN), connect work cables to are set correctly. See Section 6-3.

OM-225 590 Page 27

5-11. Making Dual Operator Mode CC Weld Connections w/ Common Work Cable
Tools Needed:

3/4 in

! INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.

 When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−) weld
terminals, and connect a single weld cable of adequate size from the Welder B (right) Negative (−) terminal to the workpiece.
 When using these connections as a common work terminal, all connections must be of the same polarity.
 For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see Section
5-17 for proper cable size).

Direct Current Electrode Positive

(DCEP) connections are shown.

Welder A (Left) Side Welder B (Right) Side

Note position
of Process
Selector
switches.

1
4

2 2

Ref. 225 543 / 802 292-A

! Stop engine. 3 Work Jumper Cable work jumper cable to Welder A (left) CC ter-
4 Common Work Cable minal.
NOTICE − Do not exceed machine duty
cycle. Connect electrode holder cables to Nega-
For Stick/TIG welding Direct Current Elec-
tive (−) terminals.
 For common work connection, work trode Positive (DCEP), connect common
If unit has the Polarity switch option, con-
cable must be able to carry combined work cable and work jumper cable to Weld-
er B (right) Negative (−) terminal. Connect nect common work cable and work jumper
weld output of both CC weld output ter- cable to Welder B (right) Work receptacle.
minals (see Section 5-17 for proper other end of work jumper cable to Welder A
(left) Negative (−) terminal. Connect other end of work jumper cable to
cable size). Welder A (left) Work receptacle.
Connect electrode holder cables to CC ter-
 Use Dual Operator mode for CC and minals. Connect electrode holder cables to Elec-
CV welding (see Section 6-1). trode receptacles.
For Stick/TIG Direct Current Electrode
1 Strain Relief  Be sure Process Selector switches
Negative (DCEN), connect common work
Route cables through strain reliefs. cable and work jumper cable to Welder B and optional Polarity switches are set
2 Electrode Holder Cables (right) CC terminal. Connect other end of correctly. See Section 6-3.

OM-225 590 Page 28

5-12. Making Dual Operator CV Weld Connections w/ Separate Work Cables
Tools Needed:

3/4 in

Direct Current Electrode Positive

(DCEP) connections are shown.

Welder A (Left) Side Welder B (Right) Side

Note position
of Process
Selector
switches.

Note position Note position

of optional of optional Po-
2 Polarity larity switch. 2
switch.
1

Ref. 225 543 / 802 292-A

! Stop engine. 3 Work Cables If unit has the Polarity switch option, con-
nect work cables to Work receptacles and
NOTICE − Do not exceed machine duty
For MIG and FCAW welding Direct Current wire feeder cables to CV receptacles.
cycle.
 Use Dual Operator mode for CC and
Electrode Positive (DCEP), connect work
cables to Negative (−) terminals and wire
 Place optional Polarity switches in Re-
verse position when using CV weld re-
CV welding (see Section 6-1). feeder cables to CV terminals.
ceptacles. There is no CV weld output
See Section 5-17 for proper cable size. when switch is in Straight position.
1 Strain Reliefs For MIG and FCAW Direct Current Elec-
trode Negative (DCEN), connect work  Be sure Process Selector and Polarity
Route cables through strain reliefs. cables to CV terminals and wire feeder switches are set correctly. See Section
2 Wire Feeder Cables cables to Negative (−) terminals. 6-3.

OM-225 590 Page 29

5-13. Making Dual Operator CV Weld Connections w/ Common Work Cable
Tools Needed:

3/4 in

! INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.

 When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−)
weld terminals, and connect a single weld cable of adequate size from the Welder B (right) Negative (−) terminal to the work-
piece.
 When using these connections as a common work terminal, all connections must be of the same polarity.
 For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see
Section 5-17 for proper cable size).

Direct Current Electrode Positive

Welder A (Left) Side (DCEP) connections are shown. Welder B (Right) Side

Note position
of Process
Selector
switches.

Note position 1
Note position of optional
of optional Polarity switch.
4
Polarity
switch.
2
2 3

Ref. 225 543 / 802 292-A

! Stop engine. 4 Common Work Cable Connect wire feeder cables to Negative (−)
terminals.
NOTICE − Do not exceed machine duty For MIG and FCAW welding Direct Current
cycle. If unit has the Polarity switch option, con-
Electrode Positive (DCEP), connect com- nect common work cable and work jumper
 For common work connection, work mon work cable and work jumper cable to
Welder B (right) Negative (−) terminal.
cable to Welder B (right) Work receptacle.
cable must be able to carry combined Connect other end of work jumper cable to
Connect other end of work jumper cable to Welder A (left) Work receptacle.
weld output of both CC weld output ter-
Welder A (left) Negative (−) terminal.
minals (see Section 5-17 for proper Connect wire feeder cables to CV recep-
cable size). tacles.
Connect wire feeder cables to CV termi-
 Use Dual Operator mode for CC and nals.  Place optional Polarity switches in Re-
CV welding (see Section 6-1). verse position when using CV weld re-
For MIG and FCAW Direct Current Elec- ceptacles. There is no CV weld output
1 Strain Relief trode Negative (DCEN), connect common when switch is in Straight position.
Route cables through strain reliefs. work cable and work jumper cable to Weld-
er B (right) CV terminal. Connect other end  Be sure Process Selector and Polarity
2 Wire Feeder Cables of work jumper cable to Welder A (left) CV switches are set correctly. See Sec-
3 Work Jumper Cable terminal. tion 6-3.

OM-225 590 Page 30

5-14. Making Dual Operator CC And CV Weld Connections w/ Separate Work Cables
Tools Needed:

3/4 in

Direct Current Electrode Positive

(DCEP) connections are shown.

Welder A (Left) Side Welder B (Right) Side

Note position
of Process
Selector
switches.

1
Note position
of optional
3 Polarity
switch. 2

4 Ref. 225 543 / 802 292-A

! Stop engine. cable to Negative (−) terminal and elec- For Stick/TIG welding on units with Polarity
trode holder cable to CC terminal. switch option, connect work cable to Work
NOTICE − Do not exceed machine duty receptacle and electrode cable to Elec-
cycle. For Stick/TIG Direct Current Electrode
Negative (DCEN), connect work cable to trode receptacle.
 Use Dual Operator mode for CC and CC terminal and electrode holder cable to For MIG/FCAW welding on units with Po-
CV welding (see Section 6-1). Negative (−) terminal. larity switch option, connect work cable to
See Section 5-17 for proper cable size.  Be sure Process Selector switches Work receptacle and wire feeder cable to
CV receptacle.
are set correctly. See Section 6-3.
1 Strain Reliefs
Route cables through strain reliefs.
For MIG and FCAW welding Direct Current  Place optional Polarity switches in Re-
Electrode Positive (DCEP), connect work verse position when using CV weld re-
2 Electrode Holder Cable cable to Negative (−) terminal and wire ceptacles. There is no CV weld output
3 Wire Feeder Cable feeder cable to CV terminal. when switch is in Straight position.
For MIG and FCAW Direct Current Elec-
4 Work Cables
trode Negative (DCEN), connect work  Be sure Process Selector and Polarity
For Stick/TIG welding Direct Current Elec- cable to CV terminal and wire feeder cable switches are set correctly. See Sec-
trode Positive (DCEP), connect work to Negative (−) terminal. tion 6-3.

OM-225 590 Page 31

5-15. Making Dual Operator CC And CV Weld Connections w/ Common Work Cable
Tools Needed:

3/4 in

! INADEQUATE CABLE CONNECTIONS can cause serious damage to welding generator and create a hazardous condition.
 When making weld connections with a common work cable, connect a weld cable of adequate size between the Negative (−)
weld terminals, and connect a single weld cable of adequate size from the Welder B (right) Negative (−) terminal to the work-
piece.
 When using these connections as a common work terminal, all connections must be of the same polarity.
 For a common work cable connection, the work cable must be able to carry the combined weld output of both modules (see
Section 5-17 for proper cable size).

Direct Current Electrode Positive Welder B (Right) Side

Welder A (Left) Side
(DCEP) connections are shown.

Note position
of Process
Selector
switches.

1
Note position of 5
optional Polarity
switch.
2
3 4

Ref. 225 543 / 802 292-A

! Stop engine. For Direct Current Electrode Positive Connect electrode holder cable to either
(DCEP), connect common work cable and Negative (−) terminal, and wire feeder
NOTICE − Do not exceed machine duty work jumper cable to Welder B (right) Neg- cable to remaining Negative (−) terminal.
cycle. ative (−) terminal. Connect other end of If unit has the Polarity switch option, con-
work jumper cable to Welder A (left) Nega-
 For common work connection, work tive (−) terminal.
nect common work cable and work jumper
cable must be able to carry combined cable to Welder B (right) Work receptacle.
weld output of both CC weld output ter- Connect other end of work jumper cable to
Connect electrode holder cable to either Welder A (left) Work receptacle.
minals (see Section 5-17 for proper CC terminal.
cable size). Connect electrode holder cable to either
Connect wire feeder cable to CV terminal Electrode receptacle.
 Use Dual Operator mode for CC and on other side. Connect wire feeder cable to CV recep-
CV welding (see Section 6-1). tacle on other side.
1 Strain Reliefs  Be sure Process Selector switches are  Place optional Polarity switch in Re-
Route cables through strain reliefs. set correctly. See Section 6-3. verse position when using CV weld re-
2 Electrode Holder Cable ceptacle. There is no CV weld output
For Direct Current Electrode Negative when switch is in Straight position.
3 Wire Feeder Cable (DCEN), connect common work cable and
4 Work Jumper Cable
work jumper cable to Welder B (right) CC  Be sure Process Selector and Polarity
terminal. Connect other end of work jumper switches are set correctly. See Section
5 Common Work Cable cable to Welder A (left) CV terminal. 6-3.

OM-225 590 Page 32

5-16. Making Single Operator CC Weld Connections

Direct Current Electrode Positive

(DCEP) connections are shown.

Welder A (left) Terminals Inactive Welder B(Right) Side

In Single Operator Mode

Note position
of Process
Selector
switch.

3 2

Tools Needed:

3/4 in Ref. 225 543 / 802 292-A

! Stop engine. Single Operator mode. (see Section to Negative (−) terminal and electrode hold-
5-10). er cable to CC terminal.
NOTICE − Do not exceed machine duty
cycle.  See Section 5-17 for proper cable size. For Stick/TIG Direct Current Electrode Neg-
ative (DCEN), connect work cable to CC
 Welder A (left) weld output terminals See Section 5-17 for proper cable size. terminal and electrode holder cable to Neg-
are disabled in Single Operator mode. 1 Strain Relief ative (−) receptacle.
Connect only to Welder B (right) termi-
nals for Single Operator mode opera- Route cables through strain reliefs. If unit has the Polarity switch option, con-
tion. 2 Electrode Holder Cable nect work cable to Work terminal and elec-
trode holder cable to Electrode receptacle.
 Use Single Operator mode for CC weld- 3 Work Cable
ing only. Welder A and Welder B CV For Stick/TIG welding Direct Current Elec-  Be sure Process Selector switch is set
weld output terminals are disabled in trode Positive (DCEP), connect work cable correctly. See Section 6-3.

OM-225 590 Page 33

5-17. Selecting Weld Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
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 Welding
Duty Duty 10 − 100% Duty Cycle
output 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)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart)
Ref. S-0007-G 2009−08

OM-225 590 Page 34

5-18. Installing Ether Cylinder (Optional Ether Starting Aid)
! Stop engine.
! Improper handling or expo-
sure to ether can harm your
health. Follow manufactur-
er’s safety instructions on
1 cylinder.
! Do not use Ether Starting Aid
while engine is running.
Open right side door.
1 Ether Cylinder
2 Nozzle
2 Remove cover and clean cylinder
nozzle.
3 Clamp
4 Fitting
5 Cap
3
6 Valve
4 Remove cap and clean fitting.
Install cylinder on fitting. Tighten
5 clamp.

 After installing cylinder, wait at

6 least 10 minutes before using
to let ether particles settle and
prevent atomizer plugging.
Put cap on fitting when cylinder is
removed.

ether1 7/96 − 153 382-A / 225 543 / 804 289-A

5-19. Remote 14 Receptacle Information

 Place Welder Selector switch in Welder A/Welder B position (dual operator mode) for both remote receptacles to work. Welder A (left) remote
receptacle output contactor and control is disabled when switch is in Welder B position.

Socket* Socket Information

24 VOLTS AC A 24 volts ac. Protected by supplementary protectors CB5 and CB6.

B Contact closure to A completes 24 volts ac contactor control circuit.

C Output to remote control; +10 volts dc in CV, 0 to +10 volts dc in CC.

REMOTE
OUTPUT D Remote control circuit common.
CONTROL
E 0 to +10 volts dc input command signal from remote control.

A/V F Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
AMPERAGE H Voltage feedback; +1 volts dc per 10 arc volts.
VOLTAGE

115 VOLTS AC 115 volts, 15 amperes, 60 Hz ac. Protected by supplementary protectors CB5 and
I
CB6.
J
Contact closure to I completes 115 volts ac contactor control circuit.

K Chassis common.
GND
G Circuit common for 24 and 115 volts ac circuits.

*The remaining sockets are not used.

OM-225 590 Page 35

 5-20. Remote 14 Receptacle Connections
Dual Operator Operation

A J
K I
B
C L N H
D M G
E F

OR

A J
K I
B
C L N H
D M G
E F

OR

Single Operator Operation

A J
K I
B
C L N H
60
0 AM
PS
D M G
E F

OR

804 289-A / Ref 225 543

OM-225 590 Page 36

 SECTION 6 − OPERATING THE WELDING GENERATOR

 When facing the front panel, the Welder B controls and weld terminals are on the right and the Welder A side controls and weld terminals are on
the left.

6-1. Engine Controls

3 1
4 5

225 543 / 804 289-A

 See Section 6-3 for weld control To Start: Press button and use Ether switch To Stop: Push switch down and hold. Re-
lease when engine stops.
descriptions. (if necessary). Release button when engine
starts. 4 Battery Charging Warning Light
1 Engine Start Button
2 Stop Switch Light goes on when battery is not charging.
3 Ether Starting Aid Switch (Optional)  If the engine does not start, let engine NOTICE − If light goes on, stop engine and
Push switch up and release while cranking come to a complete stop before attempt- check alternator and engine belt.
engine to release ether. ing restart. 5 Engine Hour Meter

OM-225 590 Page 37

6-2. Weld Controls (See Section 6-3)

300 AMPS 300 AMPS

WELDER A Welder B

600 AMPS

Welder B

60
0 AM
PS

10

2 3 4 5

9 8 7 6

Ref. 225 543 / 191 848 / 804 289-A

OM-225 590 Page 38

6-3. Weld Control Descriptions (See Section 6-2)

1 Welder Selector Switch 3 Arc Force (Dig) Control 6 Weld Meters

Use switch to select Dual Operator or Single Use control to automatically increase amper- With Process Selector switch in the Stick/Tig
Operator welding mode. age as arc length is decreased to assist in arc position, meters read 0 (zero) with contactor
Place switch in Welder A/Welder B (dual oper- starts and reduce the chance of the electrode off. Meters display actual output voltage and
ator) position for CC and CV output from Weld- sticking in the puddle. Turn clockwise to in- amperage with contactor on.
er A (left) and Welder B (right) weld output ter- crease short-circuit amperage. Set at mini-
minals. Control the weld output from the termi- mum for TIG welding. With Process Selector switch in the MIG posi-
nals on each side using the weld controls on tion, voltmeter displays preset voltage with
that same side. 4 Hot Start Switch contactor off. Voltmeter and ammeter display
Place switch in Welder B (single operator) actual output voltage and amperage with con-
Use switch to disable hot start circuit. Turn
position for CC weld output from Welder B tactor on.
switch On for Stick (SMAW) and Submerged
(right) weld output terminals only. CV weld out- Arc (SAW) Welding, and Air Carbon Arc Cut- 7 High Temperature Shutdown Light
put terminals on both sides do not work when ting and Gouging (CAC-A). Turn switch Off for
unit is in Single Operator mode. TIG (GTAW) welding. Light goes on and weld output stops if weld
rectifier gets too warm. Let unit cool before
 Welder A (left) weld output terminals are When switch is in On position, higher short-cir- welding.
disabled in Single Operator mode. Con- cuit amperage helps arc starting. After arc
nect only to Welder B (right) terminals for starts, the front panel or remote Amperage/ 8 Remote Amperage/Voltage Control
Single Operator operation. Voltage control setting determines weld am- Switch
 When in single Operator mode, only CC perage.
For front panel control, place switch in Panel
weld output is available. Welder A (left) position. For remote control, place switch in
and Welder B (right) side CV weld output  The hot start circuit does not function Remote position, and connect remote device
terminals are disabled in Single Operator when constant voltage (CV) welding. (see Section 5-19).
mode. (see Section 5-10).
5 Amperage/Voltage Control 9 Output (Contactor) Switch
2 Process Selector Switch
Use switch to select output for weld process. When Process Selector switch is in the Stick/ For front panel control of output, place switch
If switch is in Stick/Tig position, place Welder TIG position, turn control clockwise to in- in On (Hot) position. For remote control of out-
Selector switch in Welder A/Welder B or Weld- crease amperage. Read amperage from outer put, place switch in Remote position, and con-
er B Position. If switch is in MIG position, place scale of control. The Amperage/Voltage con- nect remote device (see Section 5-19).
Welder Selector switch in Welder A/Welder B trol adjusts amperage only when constant cur-
position only. rent (CC) welding and does not adjust open- ! Weld output terminals are energized
circuit voltage. when Output (Contactor) switch is On
 CV weld output for MIG is only available and engine is running.
when Welder Selector switch is in Welder When Process Selector switch is in the MIG
A/Welder B position. All weld output position, turn control clockwise to increase 10 Polarity Switch (Optional)
stops if either Process Selector switch voltage. Voltmeter value changes as control
is placed in MIG position when Welder knob is turned. Control can be adjusted while NOTICE − Do not switch under load.
Selector switch is in Welder B position. welding.
Use switch to change polarity of weld output
 Place optional Polarity switch in Reverse  When Welder Selector switch is in Welder (see Sections 5-9 thru 5-16).
position when using CV weld output. B position (single operator mode), weld
There is no CV weld output when Polarity amperage is two times the value selected  Place optional Polarity switch in Reverse
switch is in Straight position. by the Amperage/Voltage control. For ex- position when using CV weld receptacle.
NOTICE − Do not switch under load or with ample, if Amperage/Voltage control is set There is no CV weld output when switch is
output on. to 250 A, weld output is actually 500A. in Straight position.

OM-225 590 Page 39

 SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. 120 Volt And 240 Volt Duplex Receptacles

4 6 3 2 5 1

190 376

! Be sure equipment connected to the faulty equipment and the GFCI Reset but- not work. 120 volts may still be present at
240 V receptacles is GFCI-pro- ton pops out. Check for damaged tools, RC2. If CB4 opens, GFCI 2 does not work.
tected. cords, plugs, etc. connected to the recep- Press button to reset.
tacle. Press button to reset receptacle and
 Generator power is not affected by resume operation.  If a supplementary protectorcontinues
position of Welder Selector switch. to open, contact Factory Authorized
 At least once a month, run engine at Service Agent.
 4 kVA/kW generator power output is weld/power speed and press Test but-
shared by all receptacles. ton to verify GFCI is working properly. Maximum output from each 120 volt GFCI
receptacle is 2.4 kVA/kW. Maximum output
1 240 V 20 A AC Receptacle RC1 5 Supplementary Protectors CB1 And
from each 240 volt duplex receptacle half is
CB2
2 120 V 20 A AC GFCI Receptacle 4.0 kVA/kW.
GFCI 1 6 Supplementary Protectors CB3 And
CB4 Total combined output from all receptacles
3 240 V 20 A AC Receptacle RC2 is 4 kVA/kW.
CB1 and CB2 protect RC1 and GFCI 1 from
4 120 V 20 A AC GFCI Receptacle overload. If CB1 or CB2 opens, RC1 does EXAMPLE: If 12 A is drawn from RC1, only
GFCI 2 not work. 120 volts may still be present at 9 A is available at GFCI 1:
Receptacles supply 60 Hz single-phase RC1. If CB2 opens, GFCI 1 does not work. (240 V x 12 A) + (120 V x 9 A) = 4.0 kVA/kW
power at weld/power speed. Press button to reset.
If a ground fault is detected, the GFCI re- CB3 and CB4 protect RC2 and GFCI 2 from  Generator power is not affected by
ceptacle(s) circuit opens to disconnect the overload. If CB3 or CB4 opens, RC2 does weld output.

OM-225 590 Page 40

 SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Routine Maintenance
! Stop engine before maintaining.

Recycle engine
 See Engine Manual and Maintenance Label
for important start-up, service, and storage
fluids.
information. Service engine more often if
used in severe conditions.

 = Check  = Change  = Clean  = Replace Reference

* To be done by Factory Authorized Service Agent
Every Section 5-7,
8 FUEL 8-4
WATER
Hours

 Fuel/Water Separator  Fuel Level  Oil Level  Oil, Fuel Spills

Every Section 8-3
50
Hours

 Air Cleaner Element  Weld Terminals

Every
100
Hours

 Battery Terminals  Air Cleaner Hoses

Every Engine
250 1/2 in.
(13 mm) Manual,
Hours Section 8-8

 Unreadable Labels Spark Arrestor  Alternator Belt Tension

Every
500
Hours

 Weld Cables  Oil  Oil Filter

Every Section 8-4,
1000 FUEL 8-9 and En-
OR SLUDGE
Hours gine Manual

Valve Clearance*  Inside Unit  FuelFilter  Drain Sludge

 Slip Rings*
 Brushes*

OM-225 590 Page 41

8-2. Maintenance Label

OM-225 590 Page 42

8-3. Servicing Air Cleaner
! Stop engine.
NOTICE − Do not run engine without air
1 3 4 cleaner or with dirty element. Engine
2
damage caused by using a damaged ele-
ment is not covered by the warranty.

 The air cleaner primary element can

be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
Optional
risk of unwarrantable equipment
5 damage when determining whether
to clean or replace the primary ele-
ment.

If you decide to clean the primary ele-

ment, we strongly recommend instal-
ling an optional safety element to pro-
vide additional engine protection.
Never clean a safety element. Re-
place the safety element after servic-
ing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
1 Housing
Keep nozzle
2 in (51 mm) 2 Safety Element (Optional)
from element. 3 Primary Element
4 Dust Cap
5 Dust Ejector
To clean air filter:
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
Blow Inspect (if present). Reinstall cap.
NOTICE − Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).

aircleaner1 2/01 − ST-153 929-B / ST-153 585 / Ref. S-0698-B

OM-225 590 Page 43

8-4. Servicing Fuel And Lubrication Systems
! Stop engine and let cool.
1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary Fuel Filter (Fuel/
Water Separator)
5 Petcock
6 Secondary Fuel Filter
7 Fuel Shutoff Valve Lever
8
8 Sludge Drain Plug
Under Left Side
Of Fuel Tank Behind To change oil and filter:
Control Panel See engine manual.
6 To drain water from fuel system:
Open primary fuel filter petcock and
drain water into metal container.
Close petcock when water-free fuel
flows.
To replace primary fuel filter:
Close shutoff valve and turn filter
counterclockwise. Remove filter.
Apply thin coat of fuel to gasket on
new filter. Install new filter and turn
3 clockwise. Open shutoff valve. Use
primer pump to prime injector sys-
tem (see Section 8-7).
1 Inspect fuel line, and replace if
cracked or worn.
To replace secondary fuel filter:
See engine manual.
To drain sludge from fuel tank:

 This procedure should only be

done by a Factory Authorized
Service Agent.
Remove Welder A (left) control
panel to access sludge drain plug.
Put metal container under drain and
remove plug. Reinstall plug when
sludge has drained.
Reinstall control panel.
! After servicing, start engine
and check for fuel leaks.
2
! Stop engine, tighten connec-
tions as necessary, and wipe
up spilled fuel.
Close doors.
OFF

FUEL ON

7
4

Tools Needed:

3/8, 7/16, 3/4 in

225 543 / 804 285-A / 013 466

OM-225 590 Page 44

8-5. Adjusting Engine Speed
Engine speed is factory set and
should not require adjustment. Af-
Engine Speed ter tuning engine, check engine
(No Load) RPM (HZ) speed with tachometer. See table
for proper no load speed. If neces-
sary, adjust speed as follows:
Weld/Power 1850 (61.6) 1 Adjustment Rod
2 Thumbwheels
Start engine and turn thumbwheels
to increase or decrease engine no
load speed.
3 Speed Control Lever
2 Rotating lever clockwise increases
3 engine speed.
! Stop engine.
Close side door.

Tools Needed:
3/8 in

804 285-A

8-6. Servicing Optional Ether Starting Aid

! Stop engine.
! Improper handling or expo-
sure to ether can harm your
health. Follow manufactur-
er’s safety instructions on
cylinder.
If engine does not start in cold
weather, check ether cylinder as
follows:
Remove cylinder from valve.

1 1 Ether Cylinder
2 Valve
3 Scale
Weigh cylinder to see if it is empty.
Be sure atomizer is not plugged and
valve fitting is clean.

3 Replace cylinder according to

Section 5-18.

33 oz 15 oz
(935 g) (425 g)

Full Empty

ether2 7/96 − 153 382-A / Ref. 225 543 / S-0692

OM-225 590 Page 45

8-7. Priming Fuel System
! Stop engine.
Open right hand side door.
1 Primer Pump
After running out of fuel or changing
fuel filters, use pump to prime fuel
system.
Push primer pump approximately
12 times to pump fuel into the injec-
tor system. Use Engine Control
switch to start engine.

225 543 / 804 286-A

OM-225 590 Page 46

8-8. Inspecting And 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.
3 Exhaust Pipe
Start engine and run several min-
utes to blow out cleanout hole. If
nothing blows out of hole, briefly
cover end of exhaust pipe with fire-
proof material.
! Stop engine and let cool.
3 Reinstall cleanout plug.
2 1

Tools Needed:
3/8 in
Ref. 800 633-B / Ref. 225 543

8-9. Checking Generator Brushes

! Stop engine and let cool.

1 Generator Brush With Spring
Mark and disconnect leads at brush hold-
er cap. Remove brushes.
Replace brushes if damaged or if brush
material is at or near minimum length.

1/2 in (13 mm)

Minimum Length

1-1/8 in (28.6 mm)

New Length

Replace
Damaged
Brushes 1

Ref 225 543 / S−0233−A

OM-225 590 Page 47

8-10. Circuit Protection
Tools Needed:

3 4

1 2

5
6

9
Ref. 802 300 / Ref. 802 292-A

! Stop engine. Fuse F4 protects Welder B (right) control opens, weld and generator power output
board PC1. If F4 opens, Welder B (right) may continue if generator maintains excita-
 When a supplmentary protector or fuse weld output stops. tion. Weld and generator power output
opens, it usually indicates a more seri- 5 Supplementary Protector CB5 stops if generator requires field flashing cir-
ous problem exists. Contact Factory cuit to restore excitation.
6 Supplementary Protector CB6
Authorized Service Agent. 7 Supplementary Protector CB7 Press button to reset supplementary pro-
tector.
1 Fuse F1 8 Supplementary Protector CB8
9 Fuses F11, F12, F13, F21, F22, F23
2 Fuse F2 Supplementary Protector CB5 protects the
These fuses protect the weld stator wind-
24 volt and 115 volt ac output to Welder A
3 Fuse F3 ings. If fuse F11, F12, or F13 opens, Welder
(left) remote receptacle RC9. If CB5 opens,
B (right) side output is erratic or low. If fuse
4 Fuse F4 Welder A (left) RC9 24 and 115 volt ac out-
F21, F22, or F23 opens, Welder A (left) side
put stops.
Open front panel. output is erratic or low.
Supplementary Protector CB6 protects the 10 Thermostats TP3 And TP4 (Internal −
Fuse F1 protects the exciter excitation 24 volt and 115 volt ac output to Welder B Not Shown)
winding. If F1 opens, there is no weld or (right) remote receptacle RC8. If CB6
opens, Welder B (right) RC8 24 and 115 volt Thermostat TP3 protects Welder A (left)
generator power output on both sides. SR2 rectifier and TP4 protects Welder B
ac output stops.
Fuse F2 protects the exciter main field ex- (right) SR3 rectifier from overheating. If
Supplementary Protector CB7 protects TP3 or TP4 opens, Welder A (left) or Welder
citation winding. If F2 opens, there is no field current regulator board PC4. If CB7
weld output on both sides. B (right) weld output stops and the High
opens, weld and generator power output on Temp. Shutdown light goes on. Wait fifteen
Fuse F3 protects Welder A (left) control both sides stops. minutes for module to cool and thermostat
board PC1. If F3 opens, Welder A (left) weld Supplementary Protector CB8 protects the to automatically reset. Reduce amperage,
output stops. generator field flashing circuit. If CB8 voltage, or duty cycle before welding.

OM-225 590 Page 48

8-11. Troubleshooting

A. Welding

Trouble Remedy

No weld output on either side; generator Place Output (Contactor) switches in On (Hot) position, or place switches in Remote position and connect
power output okay at ac receptacles. remote contactors to remote receptacles RC8 and RC9 (see Section 6-3).

Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP3 and
TP4 to reset (see Section 8-10).

Check position of Process Selector switches and Welder Selector switch. All weld output stops if
either Process Selector switch is placed in CV position when Welder Selector switch is in Welder B
position (see Sections 6-1 and 6-3).

Check fuse F2, and replace if open (see Section 8-10). Have Factory Authorized Service Agent
check field current regulator board PC4.

Have Factory Authorized Service Agent check field current regulator board PC4 and Welder Selector
switch S2.

No weld output on either side and no Disconnect equipment from generator power receptacles during start-up.
generator power output at ac recep-
tacles.

Check fuse F1, and replace if open (see Section 8-10).

Reset supplementary protectors CB7 and/or CB8 (see Section 8-10).

Have Factory Authorized Service Agent check brushes and slip rings, field excitation circuit, rotor, stator,
and field current regulator board PC4.

No Welder A (left) weld output; Welder B Check fuse F3, and replace if open (see Section 8-10).
(right) weld output okay.

Check position of Welder Selector switch. Welder A (left) weld output stops when Welder Selector
switch is placed in Welder B position (see Section 6-1).

Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP3 to
reset (see Section 8-10).

Have Factory Authorized Service Agent check Welder A (left) contactor circuit.

No Welder B (right) weld output; Welder Check fuse F4, and replace if open (see Section 8-10).
A (left) weld output okay;

Unit overheated (High Temp. Shutdown light goes on); wait several minutes for thermostat(s) TP4 to
reset (see Section 8-10).

Have Factory Authorized Service Agent check Welder B (right) contactor circuit.

Low Welder A (left) weld output; Weld- Check position of Process Selector switch (see Section 6-3).
er B (right) output okay.

Increase Amperage/Voltage control setting.

Check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have Factory Authorized
Service Agent check main rectifier SR2.

Have Factory Authorized Service Agent check main rectifier SR2, synchronization transformers T5,
T6 and T7, and control board PC1.

Low Welder B (right) weld output; Check position of Process Selector switch (see Section 6-3).
Welder A (left) weld output okay.

Increase Amperage/Voltage control setting.

Check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have Factory Authorized
Service Agent check main rectifier SR3.

Have Factory Authorized Service Agent check main rectifier SR3, synchronization transformers T8,
T9 and T10, and control board PC5.

OM-225 590 Page 49

 Trouble Remedy
Low weld output on both sides. Check engine speed, and adjust if necessary (see Section 8-5).

Check position of Process Selector switch(s) (see Section 6-3).

Increase Amperage/Voltage controls settings.

Have Factory Authorized Service Agent check field current regulator board PC4.

High weld output on both sides. Have Factory Authorized Service Agent check field current regulator board PC4.

Erratic weld output on either side. Check and tighten connections inside and outside unit.

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Check Process Selector switch(s) connections and contacts.

Welder A (left) side: check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have
Factory Authorized Service Agent check main rectifier SR2.
Welder B (right) side: check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have
Factory Authorized Service Agent check main rectifier SR3.

Have Factory Authorized Service Agent check Welder Selector switch S2.

Low open-circuit voltage on both sides. Check engine speed, and adjust if necessary (see Section 8-5).

Have Factory Authorized Service Agent check field current regulator board PC4.

Low open-circuit voltage on either side. Increase Amperage/Voltage control setting.

Welder A (left) side: check fuses F21, F22, and F23, and replace if open. If fuse(s) are open, have
Factory Authorized Service Agent check main rectifier SR2.
Welder B (right) side: check fuses F11, F12, and F13, and replace if open. If fuse(s) are open, have
Factory Authorized Service Agent check main rectifier SR3.

Have Factory Authorized Service Agent check main rectifiers SR2 and SR3, synchronization trans-
formers T5 thru T10, and control board PC1 or PC5.

No control of weld output on either Place A/V Control switch in Panel position, or place switch in Remote position and connect remote
side. control to remote receptacle RC8 or RC9 (see Sections 5-19 and 6-3).

Have Factory Authorized Service Agent check control board PC1 or PC5.

No voltage control on either side; open- Repair or replace remote device.

circuit voltage present.

Place A/V Control switch in Panel position, or place switch in Remote position and connect remote
control to remote receptacle RC8 or RC9 (see Sections 5-19 and 6-3).

Check connections to Remote receptacle RC8 and RC9.

Have Factory Authorized Service Agent check control board PC1 or PC5.

Wire feeder does not work (either side). Reset Welder A (left) circuit breaker CB5 or Welder B (right) circuit breaker CB6 (see Section 8-10).

Check position of Process Selector switches and Welder Selector switch. All weld output stops if
either Process Selector switch is placed in CV position when Welder Selector switch is in Welder B
position (see Sections 6-1 and 6-3).

Check connections to Remote 14 receptacle RC8 (see Section 5-19).

Place optional Polarity switches in Reverse position. There is no CV weld output when Polarity switch
is in Straight position.

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

Repair or replace wire feeder.

OM-225 590 Page 50

B. Generator Power

Trouble Remedy

No output at generator power ac recep- Reset receptacle supplementary protectors (see Section 7-1).
tacles.

Press GFCI reset button on 120 volt GFCI receptacles (see Section 7-1).

Check fuse F1, and replace if open (see Section 8-10).

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

Have Factory Authorized Service Agent check brushes and slip rings.

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

C. Engine

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

Check battery connections and tighten if necessary.

Circuit breaker CB12 may have tripped. CB12 automatically resets when fault is corrected. Have Factory
Authorized Service Agent check wiring harness and components.

Engine cranks but does not start. Check fuel level (see Section 5-7).

Open fuel valve (see Section 5-7).

Check battery voltage, and replace battery if necessary. Check engine charging system according to en-
gine manual.

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

Air in fuel system. Use primer pump to prime fuel system (see Section 8-7).

See engine manual.

Engine suddenly stops. Check oil level (see Section 5-7). Automatic shutdown system stops engine if oil pressure is too low or
oil temperature is too high. Automatic shutdown system is inhibited for 30 seconds after start−up.

See engine manual.

Engine slowly stopped and cannot be re- Check fuel level (see Section 5-7).
started.

Check engine air and fuel filters (see Sections 8-3 and 8-4).

Engine hard to start in cold weather. Use starting aid switch (see Section 6-1).

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

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

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

Battery discharges between uses. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator and connections according to engine manual.

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

OM-225 590 Page 51

 SECTION 9 − ELECTRICAL DIAGRAMS

Figure 9-1. Circuit Diagram For Welding Generator

OM-225 590 Page 52
 225 565-C

OM-225 590 Page 53

 SECTION 10 − RUN-IN PROCEDURE
run_in3 2007−05

10-1. Wetstacking
! Do not perform run-in
procedure at less than 20
2 volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
1 Welding Generator
Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
1  Do not idle engine longer than
necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generator is kept loaded during
run-in.
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-225 590 Page 54

10-2. 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
from flammables.
! Do not perform run-in
procedure at less than 20
4 volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
2
1 Load Bank
1 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 Welder Selector switch in
Welder B position (600 Amps), A/V
control in minimum position, and
both Process Selector switches in
Stick/TIG position.
3 Weld Cables
Connect load bank to generator
Welder B (right) weld output termi-
nals using proper size weld cables
with correct connectors. Observe
correct polarity.
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator A/V control so load
equals 350 Amps at 40 volts.
3 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.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.
! Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0683

OM-225 590 Page 55

10-3. 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 Welder Selector switch in
Welder B position (600 Amps), A/V
control in minimum position, and
both Process Selector switches in
Stick/TIG position.
3 Weld Cables
Connect grid to generator Welder B
(right) weld output terminals using
proper size weld cables with cor-
rect connectors (polarity is not im-
portant).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
3 5 shown, if not provided on generator.
Start engine and run for several
minutes.
Set grid switches and then adjust
generator A/V control so load
equals 350 Amps at 40 volts.
4 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.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.
! Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.

S-0684

OM-225 590 Page 56

 SECTION 11 − GENERATOR POWER GUIDELINES
 The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
11-1. Selecting Equipment
1 Generator Power Receptacles
− Neutral Bonded To Frame
2 3-Prong Plug From Case
Grounded Equipment
3 2-Prong Plug From Double
Insulated Equipment
 Be sure equipment has double
1 insulated symbol and/or word-
ing on it.
! Do not use 2-prong plug un-
less equipment is double in-
2 sulated.

OR

gen_pwr 2008−01 − ST-800 577

11-2. Grounding Generator To Truck Or Trailer Frame

! Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
! Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
1 Equipment Grounding
Terminal (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
1 2 insulated copper wire.

GND/PE
 Electrically bond generator
frame to vehicle frame by met-
al-to-metal contact.
! Bed liners, shipping skids,
and some running gear insu-
late the welding generator
from the vehicle frame. Al-
3
ways connect a ground wire
from the generator equip-
ment grounding terminal to
bare metal on the vehicle
frame as shown.
! If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.

800 652-D

OM-225 590 Page 57

11-3. Grounding When Supplying Building Systems
1 Equipment Grounding
Terminal
2 Grounding Cable
Use #10 AWG or larger insulated
1 2 copper wire.
GND/PE 3 Ground Device
 Use ground device as stated in
electrical codes.
! Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
! Also see AWS Safety &
2 3 Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.

ST-800 576-B

11-4. How Much Power Does Equipment Require?

1 Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2 Non-Resistive Load
Equipment with a motor is a non-re-
sistive load and requires approxi-
mately six times more power while
starting the motor than when running
(see Section 11-8).
3 3 Rating Data
VOLTS 115
2 AMPS 4.5 Rating shows volts and amperes, or
1 Hz 60 watts required to run equipment.
Amperes x Volts = Watts
Example 1: If a drill uses 4.5 am-
peres at 115 volts, calculate its run-
ning power requirement in watts.
4.5 A x 115 V = 520 W
3
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Ex-
ample 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.

S-0623

OM-225 590 Page 58

11-5. Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Split Phase 1/8 HP 800 300
1/6 HP 1225 500
1/4 HP 1600 600
1/3 HP 2100 700
1/2 HP 3175 875
Capacitor Start-Induction Run 1/3 HP 2020 720
1/2 HP 3075 975
3/4 HP 4500 1400
1 HP 6100 1600
1-1/2 HP 8200 2200
2 HP 10550 2850
3 HP 15900 3900
5 HP 23300 6800
Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000
5 HP 23300 6000
7-1/2 HP 35000 8000
10 HP 46700 10700
Fan Duty 1/8 HP 1000 400
1/6 HP 1400 550
1/4 HP 1850 650
1/3 HP 2400 800
1/2 HP 3500 1100

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

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

OM-225 590 Page 59

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

OM-225 590 Page 60

11-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

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

1 Motor Start Code

2 Running Amperage
3 Motor HP
4 Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
4 AC MOTOR multiply running amperage by six to
2
1 VOLTS 230 AMPS 2.5 find starting amperage.
3 CODE M Hz 60 Step 2: Find Motor HP and Volts.
HP 1/4 PHASE 1 Step 3: Determine starting amper-
age (see example).
Welding generator amperage out-
put must be at least twice the
motor’s running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amper-
age required for a 230 V, 1/4 HP mo-
tor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.

S-0624

11-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.
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-225 590 Page 61

11-10. Typical Connections To Supply Standby Power
! Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
! Properly install and ground
4 this equipment according to
1 2 3
its Owner’s Manual and na-
Fused tional, state, and local codes.
Utility Welding
Disconnect
Electrical Transfer Switch Generator  Customer-supplied equipment
Switch
Service Output
(If Required) is required if generator will sup-
ply standby power during
emergencies or power out-
ages.
1 Utility Electrical Service
5 2 Transfer Switch (Double-Throw)
Switch transfers the electrical load
Essential from electric utility service to the
Loads generator. Transfer load back to
electric utility when service is re-
stored.
Install correct switch (customer-
supplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customer-
supplied) if required by electrical
code.
4 Welding Generator Output
Generator output voltage and wir-
ing must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low volt-
age and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the prem-
ises. If generator does not produce
enough output to meet all require-
ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 11-4).

OM-225 590 Page 62

11-11. 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-225 590 Page 63
 SECTION 12 − PARTS LIST

 Hardware is common and

not available unless listed.

26
25
27

24
5
6 28
7 29
8 30−See Fig. 12-4
19 20
4 9 18 21
10
17
16
3 11 22
12 23
2
13
1 14 15 31 32
101 9
10
10
9 33
34
94−See Fig. 12-2 35 36
100
37
99
38
39
40
96 41
97
81
98

95
93 82
83
92
84

85
87
86
89 88
91 90

Figure 12−1. Main Assembly

OM-225 590 Page 64
 53

50 51

49 52

48

102

47
54
46
55
56
57
45−See Fig. 12-3 49
43

58

44
42
62

61
60

59

80 63

79

78 66
77 64
37 65
38 67
68
69
72 70
71
73
74
76−See Fig. 12-5 39
40

75

804 287-A

OM-225 590 Page 65

 Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 12−1. Main Assembly
.. 1 . . . . . . . . . . . . . 605 288 . . FITTING, pipe galv plug sqhd .250NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 2 . . . . . . . . . . . . . 070 010 . . BOLT, J stl .250-20 x 2.750 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 3 . . . . . . . . . . . . . 088 696 . . STRAP, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 4 . . . . . . . . . . . . . 134 771 . . PLUG, protective .640sq . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 5 . . . . . . . . . . . . . 184 675 . . TANK, fuel 22.3gal (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 6 . . . . . . . . . . . . . 182 022 . . . . CAP, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 7 . . . . . . . . . . . . . 020 185 . . FITTING, pipe brs elbow st 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 8 . . . . . . . . . . . . . 053 525 . . FITTING, hose brs barbed M 5/16tbg x 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . 1
.. 9 . . . . . . . . . . . . . 172 071 . . CLAMP, hose .520-.605clp dia slfng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
.. 10 . . . . . . . . . . . . 134 835 . . HOSE, SAE .312 ID x .560 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . 9ft
.. 11 . . . . . . . . . . . . 097 507 . . STRIP, rbr adh back .125 x 1.000 x 20.500 60 duro . . . . . . . . . . . . . . . . . . . . 2
.. 12 . . . . . . . . . . . . 010 314 . . VALVE, shut-off fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 13 . . . . . . . . . . . . 039 599 . . FITTING, brs barbed M 5/16 tbg x 1/4 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.. 14 . . . . . . . . . . . +048 227 . . UPRIGHT, base front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 15 . . . . . . . . . . . . 170 689 . . FRAME, mtg reactor and fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 16 . . . . . . . . . . . +170 617 . . UPRIGHT, base center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 17 . . . . . . . . . . . . 017 479 . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 18 . R3, R5 . . . 097 459 . . RESISTOR, WW fxd 375W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 19 . . . . . . . . . . . . 216 565 . . BRACKET, mounting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 20 . . TD1 . . . . 214 928 . . TIMER, delay on make/break open 30 sec 12vdc . . . . . . . . . . . . . . . . . . . . . 1
.. 21 SR4, SR5 . . 035 704 . . RECTIFIER, Integ bridge 40. amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 22 . . CR5 . . . . 090 104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
.. 23 . . CB12 . . . . 205 927 . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . . . 1
.. 24 . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 25 . . . . . . . . . . . . 124 941 . . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 26 . . . . . . . . . . . . 208 353 . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 27 . . . . . . . . . . . . 032 453 . . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 28 . . . . . . . . . . . . 190 896 . . BATTERY, stor 12v 660 crk 110 rsv gp 24 low . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 29 . . . . . . . . . . . . 010 460 . . STUD, stl .312-18 x 10.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 30 SR2, SR3Figure 12−5. . . RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 31 . . . . . . . . . . . . 013 466 . . LABEL, fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 32 . . . . . . . . . . . . 145 282 . . FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT . . . . . . . . . . . . . . . . 2
.. 33 . . . . . . . . . . . . 202 242 . . BASE, fuel filter assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 34 . . . . . . . . . . . . 192 744 . . FILTER, fuel spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 35 . . . . . . . . . . . . 135 205 . . NUT, 625-11 .94 hex .76H stl pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
.. 36 . . . . . . . . . . . . 116 707 . . SUPPORT, front engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 37 . . . . . . . . . . . . 119 849 . . SCREW, 625-11 x 4.00 hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
.. 38 . . . . . . . . . . . . 071 731 . . WASHER, flat stl .656 ID x 2.250 OD x .187thk . . . . . . . . . . . . . . . . . . . . . . . 4
.. 39 . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
.. 40 . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
.. 41 . . . . . . . . . . . . 072 848 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 50 dur . . . . . . . . . . . . . . 2
.. 42 . . . . . . . . . . . . 010 875 . . CLAMP, muffler 2.000 dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 43 . . . . . . . . . . . . 105 734 . . PIPE, muffler extension elbow 1.750 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 44 . . . . . . . . . . . . 176 232 . . BAFFLE, air muffler exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 45 . . . . . . . . Figure 12−3. . . SIDE CONTROL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 46 . . . . . . . . . . . +105 909 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 47 . . . . . . . . . . . . 192 041 . . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 48 . . . . . . . . . . . . 035 968 . . WASHER, flat rbr 3.625 ID x 5.875 OD x .062thk . . . . . . . . . . . . . . . . . . . . . . 1
.. 49 . . . . . . . . . . . . 158 610 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.. 50 . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 51 . . . . . . . . . . . +192 313 . . DOOR, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 52 . . . . . . . . . . . . 222 513 . . LABEL, warning falling equipment can cause serious . . . . . . . . . . . . . . . . . . 2
.. 53 . . . . . . . . . . . . 117 257 . . PANEL, end engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 54 . . . . . . . . . . . +192 314 . . DOOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 55 . . . . . . . . . . . . 225 589 . . LABEL, diesel engine maintenance f−3l914 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 56 . . . . . . . . . . . . 004 130 . . BRACKET, support door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

OM-225 590 Page 66

 Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 12−1. Main Assembly (Continued)
. . 57 . . . . . . . . . . . . 087 341 . . BUMPER, door 1.000 OD x .750 high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 58 . . . . . . . . . . . . 087 336 . . LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 59 . . . . . . . . . . . . 048 213 . . BAFFLE, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 194 467 . . WASHER, flat (for baffle) 6.25 ID x 11.50 OD x .62 T buna . . . . . . . . . . . . . 1
. . 60 . . . . . . . . . . . . 023 313 . . CLAMP, hose 3.250-3.000 clp dia slftg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 61 . . . . . . . . . . . . 225 643 . . TUBE, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 62 . . . . . . . . . . . . 225 642 . . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 63 . . . . . . . . . . . . 189 764 . . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 64 . . . . . . . . . . . . 165 785 . . HOSE, air cleaner 2.500 id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *192 938 . . FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . *♦192 939 . . FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 65 . . . . . . . . . . . . 203 462 . . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 66 . . . . . . . . . . . . 237 006 . . ENGINE, Deutz dsl elec D914L03i (includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *064 677 . . . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *064 686 . . . . FILTER, fuel secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *066 271 . . . . V−BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 199 507 . . HOSE ASSY, oil drain 20.000 lg (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 67 . . . . . . . . . . . . 165 271 . . . . VALVE, oil drain 3/8−18 nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 68 . . . . . . . . . . . . 176 529 . . FTG, hose brs barbed fem 1/2 tbg x 3/8 npt . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 69 . . . . . . . . . . . . 113 854 . . . . HOSE, sae .500 id x .780 od xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66ft
. . . . . . . . . . . . . . . . . . 023 562 . . CLAMP, hose .312 − .875 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 70 . . . . . . . . . . . . 176 528 . . FTG, hose brs barbed elbow m 1/2 tbg x 1/2 npt . . . . . . . . . . . . . . . . . . . . . 1
. . 71 . . . . . . . . . . . . 206 906 . . ADAPTER, oil drain fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 72 . . . . . . . . . . . . 047 235 . . WASHER, seal oil copper .879id x 1.059od 111−8737 . . . . . . . . . . . . . . . . . . 1
. . 73 . . . . . . . . . . . . 195 746 . . SENDER, coolant temp & 130c switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 74 . . . . . . . . . . . . 195 745 . . SWITCH, pressure oil 1.5 bar nc cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 75 . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 60 dur . . . . . . . . . . . . . . 2
. . 76 . . . . . . . . Figure 12−4. . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 77 . . . . . . . . . . . . 225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . . . 2
. . 78 . . . . . . . . . . . . 176 236 . . BAFFLE, air outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 79 . . . . . . . . . . . . . . . . . . . . . . . CLAMP, muffler (included with engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 80 . . . . . . . . . . . . 105 733 . . PIPE, muffler extension elbow 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 81 . . . . . . . . . . . . 165 739 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 82 . . . . . . . . . . . . 191 446 . . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . . . 2.1ft
. . 83 . . . . . . . . . . . . 173 352 . . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . 2.4ft
. . 84 . . . . . . . . . . . . 192 305 . . TRAY, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 85 . . . . . . . . . . . . 176 167 . . NUT, 250-20 acorn nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 86 . . . . . . . . . . . . 192 303 . . ANGLE, mtg stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 87 . Z1, Z2 . . . 192 296 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 88 . . . . . . . . . . . . 205 791 . . BRACKET, mtg fuse assembly (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 89 . . . . . . . . . . . . 204 965 . . . . STRIP, insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 90 . . . . . . . . . . . . . 026947 . . . . STAND-OFF, insul .250-20 x 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . 91 F11-13, F21-23 . 027 267 . . FUSE, link 300 A 250 volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 92 . . . . . . . . . . . . 192 304 . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 93 . . . . . . . . . . . . 233 953 . . LABEL, warning general precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 94 . . . . . . . . Figure 12−2. . . FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 95 . . . . . . . . . . . . 175 256 . . INSULATOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 96 . . . . . . . . . . . . 192 300 . . SHROUD, generator LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 97 . T2, T4 . . . 192 371 . . TRANSFORMER, 115V pri 24VCT 8A w/leads . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 98 . . . . . . . . . . . . 192 301 . . SHROUD, generator RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 99 . . . . . . . . . . . . 168 829 . . TRANSDUCER, current 1000A module max open loop . . . . . . . . . . . . . . . . 2
. 100 . . . . . . . . . . . . 192 299 . . SHROUD, generator center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 101 . . . . . . . . . . . . 194 021 . . CAPACITOR ASSEMBLY, (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . 162 817 . . . . BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . C15, C20 . . 163 535 . . . . CAPACITOR, elctlt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . R4, R6 . . . 140 002 . . . . RESISTOR, WW fxd 10W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 162 799 . . . . BRACKET, mtg capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

OM-225 590 Page 67

 Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 12−1. Main Assembly (Continued)

. 102 . . . . . . . . . . . . 233 088 . . LABEL, danger using a generator indoors can kill you in minutes (unit) . . . 1
. . . . . . . . . . . . . . . . . . 193 501 . . KIT, label (includes safety and informational labels) . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label
individually or as part of Label Kit 193 501
*Recommended Spare Parts.
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

 Hardware is common and

not available unless listed.

6 7
8
5 9
4
3
2 12
13

11 14
10
15

1
16

28 22
29 13
42 27
30
26
31
32 12
18
24 21 17
41 25
40 23
36 18
37 22 20 19
31 21
38
39 35

33
34

804 290-A

Figure 12−2. Front Panel

OM-225 590 Page 68
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12−2. Front Panel (Figure 12−1. Item 94)

. . 1 . . . . . . . . . . . . . 225 550 . . PANEL, front control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . 209 056 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 3 . . . . . . . . . . . . . 206 795 . . BOOT, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 4 . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and serial number) . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . 190 375 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . 216 270 . . PANEL, aux power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . GFCI1,2 . . 151 981 . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . . . . 2
. . 8 . . CB1-4 . . . 093 996 . . SUPPLEMENTARY PRO, man reset 1p 20a 250vac frict . . . . . . . . . . . . . . . 4
. . 9 . RC1, RC2 . . 193 257 . . RECEPTACLE, str dx grd 2P3W 15/20A 250V . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 10 . . R10 . . . . 189 699 . . RESISTOR, WW tap 375W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . 038 620 . . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 12 . TE1,2 . . . . 038 621 . . BLOCK, term 30A 4 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 13 . T5 - 10 . . . 210 636 . . TRANSFORMER, control 6VA 120VCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 14 . . PC4 . . . . 191 255 . . CIRCUIT CARD ASSEMBLY, field current regulator . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . 083 147 . . GROMMET, SCR NO 8/10 panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 16 . . . . . . . . . . . . 192 332 . . PANEL LAYOUT, mtg component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . CB7,8 . . . . 139 266 . . SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . 206 795 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 18 . . 1T,2T . . . . 190 210 . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . . . . . . . . . . . 083 030 . . STUD, brs .250-20 x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . 010 381 . . CONNECTOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . T1, T3 . . . 192 367 . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 22 . . . . . . . . . . . . 184 649 . . HOLDER, fuse mintr .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 23 . . F3,4 . . . *012 643 . . FUSE, mintr gl slo-blo 1A, 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 24 . . F1,2 . . . *125 847 . . FUSE, mintr cer slo-blo 12A, 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 25 . . . . . . . . . . . . 129 351 . . SCREW, 008−32x .50 hexwhd.34d stl pld slffmg tap−rw . . . . . . . . . . . . . . . . 2
. . 26 . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . C1 . . . . . 087 110 . . CAPACITOR, elctlt 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . SR1 . . . . 035 704 . . RECTIFIER, integ bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . S2 . . . . . 192 292 . . SWITCH, paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 30 . . . S4 . . . ♦021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 31 . . PB1 . . . . 046 433 . . SWITCH, pb mc no spst 35a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . S14 . . . . . 199 691 . . SWITCH,tgl spdt 6a 125vac on−none−mc spd term . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . . . . . . . . . . 083 030 . . STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 34 . . . HM . . . . . 210 424 . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 35 . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 36 . . PL1 . . . . . 188 266 . . LIGHT, ind red lens 13V (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 37 . . . . . . . . . . . . 082 788 . . . . HOLDER, light ind only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 38 . . . . . . . . . . . . 048 155 . . . . BULB, incand min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . 082 789 . . . . LENS, light ind red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 40 . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . 111 785 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 42 . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and serial number) . . . . . . . . . 1
*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-225 590 Page 69

  Hardware is common and
not available unless listed.

31
32
30
29

2 33
34
28
27 7 8
6
26 5
3
4 9

25 10
11 13
24 14

23
35
22
36

21
15
12
20 16
19 18
17

802 320-A

Figure 12−3. Side Control Panels − Welder B (Right) Side Shown

OM-225 590 Page 70
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12−3. Side Control Panels (Figure 12−1. Item 45)

. . 1 . . . . . . . . . . . . +192 330 . . PANEL, side output RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 1 . . . . . . . . . . . . +192 325 . . PANEL, side output LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . 027 434 . . LABEL, welder will not start by applying power to terminals . . . . . . . . . . . . . 2
. . 3 . . . . . . . . . . . . . 010 828 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 4 . . . . . . . . . . . . . 086 074 . . TUBING, cop .540 ID x .123 wall x .562 − welder A (left) side only . . . . . . . 1
. . 5 . . S1, S9 . . . 204 903 . . SWITCH, mode single w/ dust cover (includes) . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . 163 557 . . . . SWITCH, mode single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 202 881 . . . . COVER, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . . 159 863 . . ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 7 . . . PC5 . . . . 204 832 . . CIRCUIT CARD ASSEMBLY, welder B (right) side control . . . . . . . . . . . . . . 1
. . . . . . . . PC1 . . . . 204 835 . . CIRCUIT CARD ASSEMBLY, welder A (left) side control . . . . . . . . . . . . . . . 1
. . 8 . CR2, CR3 . . 000 770 . . RELAY, encl 24VDC 3PDT 10A/120VAC 11 pin . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . GRD . . . . 185 011 . . STUD, primary board brs 10-32 x 1.592 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 10S3,6,7,8,10,11 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 11 R1,2,7,8 . . . 035 897 . . POTENTIOMETER, cp std slot 1t 2w 1k linear . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 12 LS1,2,3,4 . . 089 645 . . SWITCH, lim 11A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 13 PC2, PC6 . . 226 095 . . CIRCUIT CARD ASSEMBLY, display w/program . . . . . . . . . . . . . . . . . . . . . . 2
. . 14 . . . . . . . . . . . . 165 316 . . STAND-OFF, No. 6-32 x .875 lg .312 hex nyl . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . 15 . . . . . . . . . . . . 097 924 . . KNOB, pointer 1.625dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 16 . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 17 . . . . . . . . . . . . 097 922 . . KNOB, pointer .875dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 18 . . . . . . . . . . . . 148 956 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . 2
. . 20 . . . . . . . . . . . . 162 815 . . PANEL, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 21 . . . . . . . . . . . . 161 297 . . CAM, switch selector 2posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 22 . . . . . . . . . . . . 170 391 . . CONNECTOR, circ protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 23 . . . . . . . . . . . . 241 432 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 24 . . . . . . . . . . . . 241 433 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 25 . . . . . . . . . . . . 192 494 . . BUS BAR, connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 26 . . . . . . . . . . . . 192 493 . . STAND-OFF, bus bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 27 C2,4,5,21,22,23 . 136 736 . . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 28 . 3T, 4T . . . 190 210 . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 29 CB5, CB6 . . 139 266 . . SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac . . . . . . . . . . 2
. . 30 RC8, RC9 . . 134 735 . . CONNECTOR, circ MS/CPC 14skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 31 PC3, PC7 . . 181 261 . . CIRCUIT CARD ASSEMBLY, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 32 . . . . . . . . . . . . 165 316 . . STAND-OFF, No. 6-32 x .875 lg .312 hex nyl . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 33 . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 34 . . . . . . . . . . ♦010 647 . . PIN, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . ♦091 067 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . ♦199 123 . . LABEL, component identification master polarity . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦199 124 . . LABEL, component identification slave polarity . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 35 PL2, PL3 . . 159 522 . . LED, yellow 2.1v 20 ma 45.0 mcd panel mtg .250 hole . . . . . . . . . . . . . . . . . 2
. . 36 . . . . . . . . . . . . 159 036 . . LENS, led clear panel mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label
individually or as part of Label Kit 193 501
♦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-225 590 Page 71

  Hardware is common and 11
not available unless listed. 8

9 10

6
7

4
3

1
5

12

13

15
14
Ref. 048 456-E

Figure 12−4. Generator

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 12−4. Generator (Figure 12−1. Item 76)

.. 1 . . . . . . . . . . . . *151 299 . . BRUSH, contact elect clrg .375 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

.. 2 . . . . . . . . . . . . . 188 387 . . BRUSHHOLDER/BRACKET ASSEMBLY, (includes) . . . . . . . . . . . . . . . . . . . 1
.. 3 . . . . . . . . . . . . . 600 270 . . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.. 4 . . . . . . . . . . . . . 152 044 . . . . CAP, holder brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
.. 5 . . . . . . . . . . . . . 173 066 . . . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 6 . . . . . . . . . . . . +205 600 . . STATOR, generator (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 7 . . . . . . . . . . . . . 039 207 . . . . BAFFLE, air generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 8 . . . . . . . . . . . . . 192 286 . . ROTOR, generator (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 9 . . . . . . . . . . . . . 024 617 . . . . RING, retaining external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 10 . . . . . . . . . . . . 053 390 . . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 11 . . . . . . . . . . . . 083 748 . . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 12 . . . . . . . . . . . . 225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . . . 2
.. 13 . . . . . . . . . . . . 195 704 . . STATOR, exciter aux pwr 120/240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 14 . . . . . . . . . . . . 173 068 . . ENDBELL, generator (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.. 15 . . . . . . . . . . . . 143 220 . . . . O-RING 2.859ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label
individually or as part of Label Kit 193 501
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-225 590 Page 72
  Hardware is common and
not available unless listed.
1

802 319

Figure 12−5. Rectifier Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 12−5. Rectifier (Figure 12−1. Item 30)

. . 1 . . . . . . . . . . . . . 205 613 . . RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . 203 001 . . RECTIFIER, Si Diode (One Side Service kit W/Varnish Coating) . . . . . . . . 1
. . . . . PLG1, PLG2 . 158 720 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

 Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase
components separately or as part of the associated wiring harness.
Item Dia. Part
No. Mkgs. No. Description Quantity

Wiring Harnesses

. . . . . . . . . . . . . . . . . . . 195 702 . . HARNESS, wiring component panel (includes) . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 188 512 . . . . SEAL, wire univ 6P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . 187 651 . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . RC13,21 . . 116 045 . . . . HOUSING, plugs and pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG17 . . 135 275 . . . . HOUSING, plugs and pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . RC19, PLG20 168 071 . . . . HOUSING, plugs and pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 192 218 . . HARNESS, wiring control box welder B (right) (includes) . . . . . . . . . 1

. . . . . . . . . . CR3 . . . 000 770 . . . . RELAY, encl 24VDC 3PDT 10A/120VAC 11 pin . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . GRD . . . . 185 011 . . . . STUD, primary board brs 10-32 x 1.592 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . S8,10,11 . . 011 609 . . . . SWITCH, tgl SPDT 15A 125VAC on-none-on . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . R7,8 . . . 035 897 . . . . POTENTIOMETER, cp std slot 1t 2w 1k linear . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . LS3, 4 . . 089 645 . . . . SWITCH, lim 11A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG27 . . 131 056 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187 651 . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG20 . . 168 071 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG9,26 . 148 439 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG12 . . 152 249 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . 153 501 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC22 . . . 168 845 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC23 . . . . 168846 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . 169 240 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1

OM-225 590 Page 73

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

Wiring Harnesses

. . . . . . . . . . . . . . . . . . . 192 208 . . HARNESS, wiring control box welder A (left) (includes) . . . . . . . . . . . 1

. . . . . . . . . . CR2 . . . 000 770 . . . . RELAY, encl 24VDC 3PDT 10A/120VAC 11 pin . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . GRD . . . . 185 011 . . . . STUD, primary board brs 10-32 x 1.592 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . S3,6,7 . . . 011 609 . . . . SWITCH, tgl SPDT 15A 125VAC on-none-on . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . R1,8 . . . 035 897 . . . . POTENTIOMETER, cp std slot 1t 2w 1k linear . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . LS1,2 . . . 089 645 . . . . SWITCH, lim 11A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG18 . . 131 056 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187 651 . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG19 . . 168 071 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG4,11 . 148 439 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG5 . . . 152 249 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . 153 501 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . 168 845 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC7 . . . . 168846 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . 169 240 . . . . CONNECTOR, housing plug pins and sockets . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 192 336 . . HARNESS, wiring unit welder B (right) (includes) . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . 4T . . . . 190 210 . . . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB6 . . . 139 266 . . . . SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac . . . . . . . 1
. . . . . . . . . . RC9 . . . 134 735 . . . . CONNECTOR, circ MS/CPC 14skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PC7 . . . 181 261 . . . . CIRCUIT CARD ASSEMBLY, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG24 . . . 115 094 . . . . HOUSING, plug and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG22 . . 168 847 . . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG23 . . 152 249 . . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG21 . . 135 556 . . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 188 512 . . . . SEAL, wire univ 6P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 192 337 . . HARNESS, wiring unit welder A (left) (includes) . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . 3T . . . . 190 210 . . . . BLOCK, term 5-3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB5 . . . 139 266 . . . . SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac . . . . . . . 1
. . . . . . . . . . RC8 . . . 134 735 . . . . CONNECTOR, circ MS/CPC 14skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PC3 . . . 181 261 . . . . CIRCUIT CARD ASSEMBLY, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG14 . . . 115 094 . . . . HOUSING, plug and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . 168 847 . . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . 152 249 . . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . 135 556 . . . . HOUSING, plug pins and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 188 512 . . . . SEAL, wire univ 6P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

................... 225 595 . . HARNESS, engine du−op (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PB1 . . . 046 433 . . . . SWITCH, pb mc no spst 35a 12vdc w/black cap . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S14 . . . 199 691 . . . . SWITCH, tgl spdt 6a 125vac on−none−mc spd term . . . . . . . . . . . . . . . . 1
. . . . . . . . . . SR4,5 . . 035 704 . . . . RECTIFIER, integ bridge 40. amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

................... 192 334 . . HARNESS, aux power panel (includes . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . GFCI1,2 . 151 981 . . . . RCPT, str dx grd 2p3w 15/20a 125v *5−20r gfi . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . RC1,2 . . 193 257 . . . . RCPT, str dx grd 2p3w 15/20a 250v *6−20r . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . CB1,2,3,4 . 093 996 . . . . SUPPLEMENTARY PRO, man reset 1p 20a 250vac frict . . . . . . . . . . . . 4

OM-225 590 Page 74

 Effective January 1, 2009
(Equipment with a serial number preface of LK or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets, Cables, and
Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
* APT & SAF Model Plasma Cutting Torches
for your local material and workmanship at the time it is shipped by Miller. THIS * Remote Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Accessory (Kits)
Miller distributor. WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or * Canvas Covers
Your distributor also gives replace any warranted parts or components that fail due to such Miller’s True Blue® Limited Warranty shall not apply to:
you ... defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which 1. Consumable components; such as contact tips,
Service time Miller will provide instructions on the warranty claim cutting nozzles, contactors, brushes, slip rings,
You always get the fast, procedures to be followed. relays, work station table tops and welding
reliable response you curtains, or parts that fail due to normal wear.
Miller shall honor warranty claims on warranted equipment listed
need. Most replacement below in the event of such a failure within the warranty time (Exception: brushes, slip rings, and relays are
periods. All warranty time periods start on the delivery date of the covered on Bobcat, Trailblazer, and Legend
parts can be in your
equipment to the original end-user purchaser, and not to exceed models.)
hands in 24 hours.
one year after the equipment is shipped to a North American 2. Items furnished by Miller, but manufactured by others,
Support distributor or eighteen months after the equipment is shipped to such as engines or trade accessories. These items are
Need fast answers to the an International distributor. covered by the manufacturer’s warranty, if any.
tough welding questions? 1. 5 Years Parts — 3 Years Labor 3. Equipment that has been modified by any party other
Contact your distributor. than Miller, or equipment that has been improperly
* Original main power rectifiers only to include SCRs,
The expertise of the diodes, and discrete rectifier modules installed, improperly operated or misused based upon
distributor and Miller is industry standards, or equipment which has not had
there to help you, every 2. 3 Years — Parts and Labor
reasonable and necessary maintenance, or equipment
step of the way. * Transformer/Rectifier Power Sources which has been used for operation outside of the
* Plasma Arc Cutting Power Sources specifications for the equipment.
* Process Controllers MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Semi-Automatic and Automatic Wire Feeders USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
* Inverter Power Sources (Unless Otherwise Stated) TRAINED AND EXPERIENCED IN THE USE AND
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)
* Engine Driven Welding Generators replacement; or, where authorized in writing by Miller in
(NOTE: Engines are warranted separately by the appropriate cases, (3) the reasonable cost of repair or
engine manufacturer.) replacement at an authorized Miller service station; or (4)
3. 1 Year — Parts and Labor Unless Specified payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
* Motor Driven Guns (w/exception of Spoolmate customer’s risk and expense. Miller’s option of repair or
Spoolguns) replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* Positioners and Controllers F.O.B. at a Miller authorized service facility as determined by
* Automatic Motion Devices Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
Electronic PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
Controls/Recorders REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
* Water Coolant Systems (Non-Integrated) CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Flowgauge and Flowmeter Regulators (No Labor) PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
* HF Units OTHER LEGAL THEORY.
* Grids ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Spot Welders ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
* Load Banks REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Fume Extractors OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Arc Stud Power Sources & Arc Stud Guns PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Racks OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Running Gear/Trailers MERCHANTABILITY OR FITNESS FOR PARTICULAR
* ICE Plasma Cutting Torches (No Labor) PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Field Options FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
(NOTE: Field options are covered under True Blue® BY MILLER.
for the remaining warranty period of the product they Some states in the U.S.A. do not allow limitations of how long an
are installed in, or for a minimum of one year — implied warranty lasts, or the exclusion of incidental, indirect,
whichever is greater.) special or consequential damages, so the above limitation or
* Bernard-Branded Mig Guns (No Labor) exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
* Weldcraft-Branded TIG Torches (No Labor) state to state.
* Subarc Wire Drive Assemblies
In Canada, legislation in some provinces provides for certain
* Work Stations/Weld Tables (No Labor) 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 Warranty
5. 90 Days — Parts provides specific legal rights, and other rights may be available,
* MIG Guns and Subarc (SAW) Guns but may vary from province to province.
miller_warr 2009−10
 Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

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

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

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2009 Miller Electric Mfg. Co. 2009−01