Motosoldadoras Miller

Processes
TM-4435B 200605
Eff. w/Serial Number LE341957
Description
Engine Driven Welding Generator
Big Blue 400 CX
)
Air Carbon Arc (CAC-A) Cut-
ting and Gouging
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
File: Engine Drive
Visit our website at
www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS FOR SERVICING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Servicing Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. California Proposition 65 Warnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. EMF Information 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 DEFINITIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturers Rating Label 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 SPECIFICATIONS 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, And Operating Angles 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Volt-Ampere Curves 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Fuel Consumption 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Duty Cycle And Overheating 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. AC Generator Power Curve 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 INSTALLATION 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Mounting Welding Generator 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Installing Exhaust Pipe 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Activating The Dry Charge Battery (If Applicable) 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting The Battery 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Engine Prestart Checks 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Connecting To Weld Output Terminals 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting Weld Cable Sizes* 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Connecting To Remote 14 Receptacle RC14 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 OPERATING CC/CV FLUX CORE WELDING GENERATOR 18 . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls (See Section 5-2) 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Description Of Front Panel Controls (See Section 5-1) 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Process/Contactor Switch 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Lift-Arct Start Procedure 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Remote Voltage/Amperage Control 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 OPERATING CC/CV WELDING GENERATOR 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls (See Section 6-2) 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Front Panel Controls (See Section 6-1) 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Process/Contactor Switch On CC/CV Models 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Lift-Arct Start Procedure 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Remote Voltage/Amperage Control 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 OPERATING AUXILIARY EQUIPMENT 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. CC Model Auxiliary Power Receptacles 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. CC/CV Model Auxiliary Power Receptacles 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 MAINTENANCE 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Caterpillar Customer Assistance 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Checking Generator Brushes 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Servicing Air Cleaner 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Inspecting And Cleaning Spark Arrestor Muffler 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Servicing Engine Cooling System 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Adjusting Engine Speed On Standard Models 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Adjusting Engine Speed On Models With Automatic Idle (Optional) 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Servicing Fuel And Lubrication Systems 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS
8-11. Overload Protection 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Optional Voltmeter/Ammeter Help Displays 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 THEORY OF OPERATION 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 TROUBLESHOOTING 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Troubleshooting Tables 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) 46 . . . . . . . . . . . . . . . .
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2) 48 . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Waveforms For Sections 10-2 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Filter Board PC6 Testing Information 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Filter Board PC6 Test Point Values 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-7. Module Testing Information 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-8. Main Control Board PC1 Testing Information 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-9. Main Control Board PC1 Test Point Values 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-10. Voltage Regulator Board PC3 Testing Information 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-11. Voltage Regulator Board PC3 Test Point Values 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-12. Meter Display Board PC2 Testing Information 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-13. Meter Display Board PC2 Test Point Values 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-14. Idle Module PC5 Testing Information And Troubleshooting Flow Chart 58 . . . . . . . . . . . . . . . . . . . . . . .
10-15. Replacing Brushes And Cleaning Slip Rings 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-16. Checking Unit Output After Servicing 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 DISASSEMBLY AND REASSEMBLY 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Disassembly Of Unit 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Disassembly Of Generator 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Other Torque Values 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4. Replacing Rectifier SCR Modules 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 ELECTRICAL DIAGRAMS 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 RUN-IN PROCEDURE 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Wetstacking 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Run-In Procedure Using Load Bank 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3. Run-In Procedure Using Resistance Grid 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 PARTS LIST EFFECTIVE WITH LE341957 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14-1. Main Assembly (CC/CV Model Shown) 82 . . . . . . . . . . . . . . . . . . . . .
Figure 14-2. Panel, Front w/Components Prior To LF350569 87 . . . . . . . . . . . . . . .
Figure 14-3. Panel, Front w/Components (CC Model) Effective W/LF350569 89
Figure 14-4. Panel, Front w/Components (CC/CV Model) Effective W/LF350569 . . . . .
91
Figure 14-5. Control Panel 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14-6. Generator 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14-7. Rectifier Assembly For CC Models 95 . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14-8. Rectifier Assembly For CC/CV Models 96 . . . . . . . . . . . . . . . . . . . . . .
dec_rot_6/05
Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
NOTE
Manufacturer: European Contact:
Miller Electric Mg. Co. Mr. Danilo Fedolfi,
1635 W. Spencer St. Managing Director
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
Phone: (920) 734-9821 Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product: Big Blue 400 CX
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Noise level of Welding Generators: 2000/14/EC
Standards
Arc Welding Equipment Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Rotating Electrical Machines Part 1: Rating and Performance.
IEC 60034-1 Ed. 10.2 1999-08
Rotating Electrical Machines Part 5: Classification Of Degrees Of Protection Provided By Enclosure Of Rotating
Electrical Machines (IP Code) IEC 60034-5 2001-06
Insulation Coordination For Equipment Within Low-Voltage Systems:
Part 1: Principles, Requirements and Tests: IEC 60664-1 Ed. 1.1 2000-04
Arc Welding Equipment Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10 August 2002
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_rotsound_6/05
Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
NOTE
Manufacturer: European Contact: Notified Body:
Miller Electric Mg. Co. Mr. Danilo Fedolfi, AV Technology Limited
1635 W. Spencer St. Managing Director AVTECH House
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l. Birdhall Lane
Phone: (920) 734-9821 Via Privata Iseo 6/E Cheadle Heath
20098 San Giuliano Stockport, Chesire SK30XU
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
The Manufacturer Declares the: Big Blue 400 CX
Conforms to Directive: 2000/14/EC, Noise Level of Welding Generators
Effective Date: 7/2004
Sound Level Information
Measured Sound Power Level: 96 dB
Guaranteed Sound Power Level: 96 dB
Sound power level requirements determined by the 30% duty cycle of 400 A, 23 V
Conforming assessment procedure 1 of Annex VI will be followed.
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
TM-4435 Page 1 Big Blue 400 CX
SECTION 1 SAFETY PRECAUTIONS FOR SERVICING
Y Warning: Protect yourself and others from injury read and follow these precautions.
1-1. Symbol Usage
OM-4435E - 200511, safety_rtm 3/06
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
.Means Note; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Servicing Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard.
Y Only qualified persons should test, maintain, and repair this
unit.
Y During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
D Do not touch live electrical parts.
D Stop engine before testing or repairing unit un-
less the procedure specifically requires an en-
ergized unit.
D Insulate yourself from ground by standing or working on dry insu-
lating mats big enough to prevent contact with the ground.
D Do not leave live unit unattended.
D When testing live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters.
D Stop engine on inverter and discharge input capacitors according
to instructions in Troubleshooting Section before touching any
parts.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans,
belts, and rotors.
D Have only qualified people remove doors,
panels, covers, or guards for maintenance
and troubleshooting as necessary.
D Keep hands, hair, loose clothing, and tools away from moving
parts.
D Before working on generator, remove spark plugs or injectors
to keep engine from kicking back or starting.
D Block flywheel so that it will not turn while working on genera-
tor components.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
FLYING METAL or DIRT can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ENGINE EXHAUST GASES can kill.
D Do not breathe exhaust fumes.
D Use in open, well-ventilated areas, or vent ex-
haust outside and away from any building air in-
takes.
FUEL can cause fire or explosion.
D Stop engine and let it cool off before checking or
adding fuel.
D Do not add fuel while smoking or if unit is near
any sparks or open flames.
D Do not overfill tank; clean up any spilled fuel.
BATTERY EXPLOSION can BLIND.
D Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
D Stop engine before disconnecting or connect-
ing battery cables.
D Do not allow tools to cause sparks when working on a battery.
D Do not use welder to charge batteries or jump start vehicles.
D Observe correct polarity (+ and ) on batteries.
D Disconnect negative () cable first and connect it last.
BATTERY ACID can BURN SKIN and EYES.
D Do not tip battery.
D Replace damaged battery.
D Flush eyes and skin immediately with water.
TM-4435 Page 2
Big Blue 400 CX
STEAM AND HOT COOLANT can burn.
D If possible, check coolant level when engine is
cold to avoid scalding.
D Always check coolant level at overflow tank, if
present on unit, instead of radiator.
D If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
D Wear safety glasses and gloves and put a rag over radiator cap.
D Turn cap slightly and let pressure escape slowly before completely
removing cap.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit and properly installed
accessories only. Do not exceed maximum lift
eye weight rating (see Specifications).
D Lift and support unit only with proper equip-
ment andcorrect procedures.
D Securely attach components to lifting equip-
ment.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
HOT PARTS can cause severe burns.
D Do not touch hot engine parts bare-handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
SHOCK HAZARD from testing.
D Stop engine before making or changing meter
lead connections.
D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
D Read instructions for test equipment.
TILTING OR TIPPING can cause injury.
D Do not put any body part under unit while lifting.
D Always use proper equipment (hoists, slings,
chains, blocks, etc.) of adequate capacity to lift
and support components (stator, rotor, engine,
etc.) as needed during job.
PINCH POINTS can injure.
D Be careful when working on stator and rotor assemblies.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with elec-
tronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the equip-
ment at once.
D Have the installation regularly checked and maintained.
D 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.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owners Manual for welding safety
precautions.
D Use only genuine replacement parts from the
manufacturer.
D Reinstall injectors and bleed air from fuel system according to
engine manual.
1-3. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1-4. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
SECTION 2 DEFINITIONS
2-1. Warning Label Definitions
3/96
1 Remove unit from shipping
crate. Remove Owners
Manual from unit. Follow
instructions to install muffler.
2 Read Owners Manual. Read
labels on unit.
3 Use Diesel Fuel only, and fill
fuel tank. Leave room for
expansion.
4 Warning! Watch Out! There
are possible hazards as
shown by the symbols. Read
Owners Manual. Follow
instructions to activate
battery.
5 Check oil level. Add oil if
necessary.
6 During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
7 After the first 50 hours of
operation, change the oil and
oil filter.
+
2
1
+
4
DIESEL
API CD-MIL L 2104D,
CD/SE, CD/SF
3
S-177 571
0 50 h Std. 0 200A 200A
5
50 h Std.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
2-2. Manufacturers Rating Label
2-3. Symbols And Definitions
Some symbols are found only on CE products.
NOTE
Stop Engine
Fast (Run, Weld/
Power)
Slow (Idle) Start Engine
Starting Aid
(Preheat)
Battery (Engine)
Engine Oil
Pressure
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive Negative
Certified/Trained
Mechanic
Welding Arc
A
Amperes
V
Volts Panel/Local Remote
Engine
Air Temperature Or
Engine
Temperature
Output
Alternating
Current
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
TIG (GTAW)
Welding
Time
h
Hours
s
Seconds
1
Single Phase
3
Three Phase
Read Operators
Manual
Circuit Protection
Do Not Switch
While Welding
Electrode
Connection
Work Connection
3
G
Engine-Driven,
Three-Phase
Alternator With
Rectifier
Hz
Hertz
X
Duty Cycle
U
0
Rated No Load
Voltage (Average) U
2
Conventional
Load Voltage
n
Rated Load
Speed
n
1
Rated Idle
Speed n
0
Rated No Load
Speed I
Current
I
2
Rated Welding
Current
Contactor On Arc Force (Dig) Lift-Arc TIG
Remote Foot
Control TIG
(GTAW)
SECTION 3 SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
Weld Output
Range
Rated Welding
Output
Maximum
Open-
Circuit
Voltage
Auxiliary Power Rating Engine
Fuel
Capacity
CC/DC
20 410 A
300 A, 32 Volts DC
60% Duty Cycle
Generator
Single-Phase,
10 kVA/kW 91/46 A CC/DC
20 410 A
60% Duty Cycle
250 A, 30 Volts DC
100% Duty cycle
73
10 kVA/kW, 91/46 A,
110/220 V AC,
60 Hz
Caterpillar 3013C
WaterCooled 11.5 gal
CV/DC
Flux Core
14 40 V
300 A, 29 Volts DC
60% Duty Cycle
250 A, 26.5 Volts DC
100% Duty cycle
73
Receptacles
110/55 V AC Receptacles
5.5 kVA/kW, 50/100 A
220/110 V AC Receptacles
11 kVA/kW, 50/20 A
Water Cooled
ThreeCylinder
21.7 HP Diesel Engine
11.5 gal
(43.5 L)
3-2. Dimensions, Weights, And Operating Angles
Dimensions
Height
32 in (813 mm)
35-3/4 in (908 mm)
(to top of lift eye)
G
Width
26-1/4 in (667 mm)
(mtg. brackets turned in)
28-3/4 in (730 mm)
(mtg. brackets turned out)
Y Do not exceed tilt angles or engine could
be damaged or unit could tip.
Y Do not move or operate unit where it could
tip.
Depth 56 in (1422 mm)
tip.
A 56 in (1422 mm)
B 54 in (1372 mm)
B
A
C
C 52 in in (1321 mm)
B
A
C
D 2 in (51 mm)
E 26 in (660 mm)
F 7/8 in (22 mm)
30
G 27-3/4 in (705 mm)
20
30
H
9/16 in (14 mm) Dia.
4 Holes
Front Panel End
H
20
20
Weight
F D
No fuel: 1100 lb (499 kg)
w/ fuel: 1199 lb (544 kg)
F
E
D
Lifting Eye Weight Rating:
1500 lb (680 kg) Maximum
DC AMPERES
0 100 200 300 400 500
0
20
40
60
80
100
D
C

V
O
L
T
S
3-3. Volt-Ampere Curves
222 108 / 221 800 / 217 518
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
A. Stick Mode
B. MIG Mode
C. TIG Mode
D
C

V
O
L
T
S
DC AMPERES
0 100 200 300 400 500
100
80
60
40
20
0
MIN MAX 300
MAX
MIN
DC AMPERES
D
C

V
O
L
T
S
0 100 200 300 400 500
0
10
20
30
40
50
60
70
80
90
100
MIN
300
MAX
3-4. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
217 509
IDLE
DC WELD AMPERES AT 100% DUTY CYCLE
U
.
S
.

G
A
L
/
H
R
.
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
0 50 100 150 200 250 300 350 400
Continuous Welding
3-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
Y Exceeding duty cycle can
damage unit and void
warranty.
100% Duty Cycle At 250 Amperes
217 515
10 15 20 25 30 40 50 60 80 100
CC
CV
1000
800
600
500
400
300
250
200
150
100
W
E
L
D

A
M
P
E
R
E
S
% DUTY CYCLE
3-6. AC Generator Power Curve
220 346B
The ac power curve shows the gen-
erator power in amperes.
AC AMPERES IN 110V MODE
AC AMPERES IN 220V MODE
A
C

V
O
L
T
S
0 20 40 60 80 100 120 140
0 10 20 30 40 50 60 70
0
20
40
60
80
100
120
0
40
80
120
160
200
240
Notes
16 Gauge (.063 in)
22 Gauge (.031 in)
24 Gauge (.025 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
MATERIAL THICKNESS REFERENCE CHART
SECTION 4 INSTALLATION
install3 6/05 Ref. 800 652 / Ref. 800 477-A / 803 274
Y Always securely fasten weld-
ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
ble codes.
Y Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
Y If unit does not have GFCI re-
ceptacles, use GFCI-protected
extension cord.
.See Section 3-2 for lifting eye
rating.
.See Section 4-2 for mounting
information.
Grounding:
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 insu-
lated copper wire.
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
GND/PE
1
2
3
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
Movement
Airflow Clearance
4-1. Installing Welding Generator
OR
Grounding
Y Bed liners, shipping skids, and some running
gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding termi-
nal to bare metal on the vehicle frame as shown.
OR
Location
OR
4-2. Mounting Welding Generator
Tools Needed:
9/16 in
2
2
4
Welding Unit In Place
Bolting Unit In Place
Y Do not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
Y Do not mount unit by sup-
porting the base only at the
four mounting brackets.
Use cross-supports to ade-
quately support unit and pre-
vent damage to base.
Mounting Surface:
1 Cross-Supports
2 Mounting Brackets (Supplied)
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brack-
ets.
3 1/2 in Bolt And Washer
(Minimum Not Supplied)
4 3/8-16 x 1 in Screws
(Supplied)
To Bolt Unit In Place:
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
1
Inadequate support.
2
Supporting The Unit
Using Mounting Brackets
install3 6/05 803 274 / 200 864-A / Ref 804 444-A
Y Do not use flexible mounts.
1
OR
3
.CC model shown.
4-3. Installing Exhaust Pipe
1/2 in
Tools Needed:
803 582F / Ref. 226 386
Y Stop engine and let cool.
.Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
4-4. Activating The Dry Charge Battery (If Applicable)
Y Always wear a face shield,
rubber gloves and protective
clothing when working on a
battery.
Remove battery from unit.
5 Vent Caps
6 Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
7 Well
Fill each cell with electrolyte to
bottom of well (maximum).
Y Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
8 Battery Charger
Y Read and follow all instruc-
tions supplied with battery
charger.
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am-
peres. Disconnect charging cables
and install battery.
.When electrolyte is low, add
only distilled water to cells to
maintain proper level.
1
Tools Needed:
2
4
30 A For 12 Minutes
5 A For 30 Minutes
OR
+
3
drybatt1 6/05 S-0886
4-5. Connecting The Battery
1/2 in
+
Y Connect Negative () Cable Last.
Tools Needed:
Ref. 804 009-C / Ref. 226 386 / S-0756-C
.Close door after connecting battery.
4-6. Engine Prestart Checks
.Check all engine fluids daily.
Engine must be cold and on a level surface.
Unit is shipped with 20W break-in oil.
Automatic shutdown system stops engine if
oil pressure is too low or coolant tempera-
ture is too high.
.This unit has a low oil pressure shut-
down switch. However, some condi-
tions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 13.
Fuel
Y Do not use gasoline. Gasoline will
damage engine.
The unit is shipped with enough fuel to pre-
vent air from entering fuel system. Add fresh
diesel fuel before starting (see engine main-
tenance label for fuel specifications). Leave
filler neck empty to allow room for
expansion.
Do not run out of fuel or air will enter fuel sys-
tem and cause starting problems. See en-
gine manual to bleed air from fuel system.
Oil
After fueling, check oil with unit on level sur-
face. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Coolant
Check coolant level in radiator before start-
ing unit the first time. If necessary, add cool-
ant to radiator until coolant level is at bottom
of filler neck.
Check coolant level in recovery tank daily.
If necessary, add coolant to recovery tank
until coolant level is between Cold Full and
Hot Full levels. If recovery tank coolant level
was low, also check coolant level in radiator.
Add coolant if level is below bottom of radia-
tor filler neck.
Unit is shipped with an engine coolant mix-
ture of water and ethylene glycol base anti-
freeze rated to 34 F (37 C). Add anti-
freeze to mixture if using the unit in tempera-
tures below 34 F (37 C).
Keep radiator and air intake clean and free
of dirt.
Y Incorrect engine temperature can
damage engine. Do not run engine
without a properly working thermo-
stat and radiator cap.
.To improve cold weather starting:
Use Preheat switch (see Section 5-1).
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.
Use correct grade oil for cold weather
(see Section 8-1).
Full
Capacity:
6 qt (5.7 L)
Diesel
Full
Hot Full
Cold Full
Check radiator coolant
level when fluid is low in
recovery tank.
Coolant Recovery Tank
Ref. 804 009C
Full
4-7. Connecting To Weld Output Terminals
Tools Needed:
3/4 in
Ref.804 009-C / Ref. 226 386 / 803 778-A
6
4
5
Do not place
anything between
Correct Installation Incorrect Installation
3
weld cable terminal
and copper bar.
Y Stop engine.
1 Work () Weld Output Terminal
2 Positive (+) Weld Output Terminal(s)
Y Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output termi-
nal. Slide weld cable terminal onto weld output
terminal and secure with nut so that weld cable
terminal is tight against copper bar. Do not
place anything between weld cable termi-
nal and copper bar. Make sure that the sur-
faces of the weld cable terminal and cop-
per bar are clean.
Stick and TIG Welding
For Stick and TIG welding Direct Current Elec-
trode Positive (DCEP), connect electrode
holder cable to Positive (+) terminal and work
cable to Negative () terminal on left.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
Use Process switch to select type of weld out-
put (see Section 5-3).
MIG and FCAW Welding
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP), connect wire
feeder cable to Positive (+) terminal and work
cable to Negative () terminal on left. Use Pro-
cess switch to select type of weld output (see
Section 5-3).
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
1
2
.CC/CV model shown.
4-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Weld Output
Terminals
Y Stop engine before
connecting to weld out-
put terminals.
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
Welding
Amperes
10 60%
Duty
Cycle
60 100%
Duty
Cycle
10 100% Duty Cycle
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)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500 2/0 (70) 3/0 (95) 4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
* This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm
2
for metric use S-0007-F
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
Notes
4-9. Connecting To Remote 14 Receptacle RC14
.CC/CV model shown. Socket* Socket Information
24 VOLTS AC
A 24 volts ac. Protected by sup-
plementary protector CB8.
24 VOLTS AC
B Contact closure to A completes
24 volt ac contactor control
circuit.
C Output to remote control:+10
volts dc in MIG mode; 0 to +10
volts dc in Stick or TIG mode.
REMOTE
OUTPUT
D Remote control circuit common.
OUTPUT
CONTROL
E DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
F
Current feedback: 1 volt per
100 amperes.
OR
H Voltage feedback: 1 volt per 10
arc volts.
GND
K Chassis common.
Ref 804 009-C
NEUTRAL G Circuit common for 24 volt ac
circuit.
*The remaining sockets are not used.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
SECTION 5 OPERATING CC/CV FLUX CORE WELDING GENERATOR
5-1. Front Panel Controls (See Section 5-2)
226 390A / 804 009C
1 2
5 4 6 7 8
9 10
3
Stop
5-2. Description Of Front Panel Controls (See Section 5-1)
Engine Starting Controls
1 Preheat Switch
Use switch to energize starting aid for cold
weather starting (see starting instructions fol-
lowing).
2 Engine Control Switch
Use switch to start engine, select engine
speed (if unit has auto idle option), and stop
engine.
In Run position, engine runs at weld/power
speed. In Auto position (optional), engine
runs at idle speed at no load and weld speed
with load applied.
3 Engine Stop Lever
Use lever to stop engine if Engine Control
switch does not work.
.The Engine Stop lever shuts off the fuel
supply. However, the Engine Stop lever
will not stop the engine if the engine can
draw fuel-rich air from the surrounding
atmosphere (oil refineries).
To Start:
Y Do not use ether.
.If engine does not start, let engine come
to a complete stop before attempting re-
start.
Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
Below 325 F (05 C): turn engine control switch
to Auto position. Push Preheat switch up for
60 seconds. Turn Engine Control switch to
Start. Release Engine Control switch and
Preheat switch when engine starts.
To Stop: turn Engine Control switch to Off
position.
Engine Gauges, Meters, And Lights
4 Fuel Gauge/Hourmeter
Use gauge to check fuel level or total engine
operating hours.
To check fuel level or engine hours when en-
gine is not running, turn Engine Control switch
to Run or Auto (optional) position.
5 Engine Indicator Light
Light goes on and engine stops if engine tem-
perature exceeds 230 F (110 C) or engine
oil pressure is below 10 psi (69 kPa).
.Normal engine temperature is 180 - 2035
F (82 - 955 C). Normal oil pressure is 30
- 60 psi (207 - 414 kPa).
Y Do not run engine until trouble is
fixed.
Weld Controls
6 Remote Control Receptacle
Use receptacle to connect remote controls
and wire feeders.
When a remote control is connected to the
Remote receptacle, the Auto Sense Remote
feature automatically switches voltage/am-
perage control to the remote control (see Sec-
tion 4-9).
If no remote control is connected to the Re-
mote receptacle, the front panel Voltage/Am-
perage control adjusts voltage and amper-
age.
.If a remote device connected to Remote
Receptacle RC14 is faulty or is discon-
nected, the meters display Help 25 (see
Section 8-12). Clear fault by stopping
and restarting the unit or by turning Pro-
cess/Contactor switch to another posi-
tion.
7 Process/Contactor Switch
See Section 5-3 for Process/Contactor
switch information.
8 Voltage/Amperage Control
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage.
With Process/Contactor switch in any Wire
(MIG) position, use control to adjust voltage.
With Process/Contactor in any Stick or TIG
mode and a remote control connected to the
remote control receptacle, high output limit is
set by the front panel Voltage/Amperage con-
trol. The remote control adjusts output be-
tween minimum and the high limit set by the
front panel control.
With Process/Contactor switch in any MIG
remote control receptacle, the front panel
Voltage/Amperage control has no effect on
weld output.
Weld Meters (Optional)
.Weld meters also work in combination to
display troubleshooting help codes (see
Section 8-12).
9 DC Voltmeter
Voltmeter displays preset voltage (MIG weld-
ing) with contactor off, and actual output volt-
age with the contactor on. Voltmeter displays
voltage at the weld output terminals, but not
necessarily the welding arc due to resistance
of cable and connections.
To set voltage, turn contactor off and turn Pro-
cess/Contactor switch to Wire position. Turn
V/A control until desired voltage is displayed
on Voltmeter. When welding is finished, volt-
meter displays weld voltage and then defaults
to preset voltage.
10 DC Ammeter
Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
output amperage when welding.
To set amperage, turn Process/Contactor
switch to Stick or TIG position. Turn V/A con-
trol until desired amperage is displayed on
Ammeter. When welding is finished, ammeter
displays weld amperage and then defaults to
preset amperage.
5-3. Process/Contactor Switch
Y Weld output terminals are ener-
gized when Process/Contactor
switch is in a Weld Terminals Al-
ways On position and the engine
is running.
Use switch to select weld process and
weld output on/off control (see table be-
low).
Place switch in Remote On/Off Switch
Required positions to turn weld output on
and off with a device connected to the
Remote 14 receptacle.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 5-4).
1
Ref 804 444A / Ref 226 390A
Process/Contactor Switch Settings
Switch Setting Process Output On/Off Control Engine Auto Idle (Optional) Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)
Remote On/Off Switch Required
TIG HF Required Or Scratch
Start
GTAW With HF Unit, Pulsing Device,
Or Remote Control
At Remote 14 Receptacle Active
Remote On/Off Switch
Required CV Feeder
Using 24 Volt Remote
Flux Core
w/Constant Speed Feeder
Weld Terminals Always On Wire
Flux Core
w/Voltage Sensing Feeder
Electrode Hot Active
Weld Terminals Always On Stick
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting And
Gouging
Weld Terminals Always On TIG
Lift-Arc
TIG Lift-Arc (GTAW) Electrode Hot Active
5-4. Lift-Arc Start Procedure
Lift-Arc t TIG
With Lift-Arct TIG selected, start
arc as follows:
1 TIG Electrode
2 Workpiece
Turn gas on. Touch tungsten
electrode to workpiece at weld start
point. Hold electrode to
workpiece for 1-2 seconds, and
slowly lift electrode. Arc is formed
when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece
without overheating, sticking, or be-
ing contaminated.
Application:
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to
replace the scratch method.
1
1 2
Seconds
Touch
Do NOT Strike Like A Match!
2
Lift-Arc Start Method
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
5-5. Remote Voltage/Amperage Control
1 Remote 14 Receptacle RC14
Connect optional remote control to RC14 (see
Section 4-9).
.When a remote control is connected to the
Remote receptacle, the Auto Sense Re-
mote feature automatically switches volt-
age/amperage control to the remote con-
trol. When a device is connected to the Re-
mote receptacle, remote voltage/amper-
age control is always available regardless
of the position of the Process/Contactor
switch.
0774 / Ref.226 390A / Ref 804 444A
Example: Remote Voltage Control (MIG)
Adjust Optional Remote Control
To Desired Weld Output
Set Remote Process
Example: Combination Remote Amperage Control (TIG)
Adjust Optional Remote Control
Set V/A Control
To Limit Max. Output:
About 205 A
In Example:
Process =Remote TIG
Min = 20 A DC
Max = About 205 A DC
Max (205 A DC)
Min (20 A DC)
Connect Remote
Control To Remote
Receptacle RC14
Connect Remote
Control To Remote
Receptacle RC14
Set Remote Process
(Only If Remote On/Off
Control Is Desired)
1
Notes
SECTION 6 OPERATING CC/CV WELDING GENERATOR
6-1. Front Panel Controls (See Section 6-2)
226 386-B / 804 009-C
1 2 5 4 6 7
8
9 10
3
Stop
6-2. Description Of Front Panel Controls (See Section 6-1)
Engine Starting Controls
1 Preheat Switch
Use switch to energize starting aid for cold
weather starting (see starting instructions fol-
lowing).
2 Engine Control Switch
Use switch to start engine, select engine
speed (if unit has auto idle option), and stop
engine.
In Run position, engine runs at weld/power
speed. In Auto position (optional), engine
runs at idle speed at no load and weld speed
with load applied.
3 Engine Stop Lever
Use lever to stop engine if Engine Control
switch does not work.
.The Engine Stop lever shuts off the fuel
supply. However, the Engine Stop lever
will not stop the engine if the engine can
draw fuel-rich air from the surrounding
atmosphere (oil refineries).
To Start:
Y Do not use ether.
.If engine does not start, let engine come
to a complete stop before attempting re-
start.
Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
Below 325 F (05 C): turn engine control switch
to Auto position. Push Preheat switch up for
60 seconds. Turn Engine Control switch to
Start. Release Engine Control switch and
Preheat switch when engine starts.
To Stop: turn Engine Control switch to Off
position.
Engine Gauges, Meters, And Lights
4 Fuel Gauge/Hourmeter
Use gauge to check fuel level or total engine
operating hours.
To check fuel level or engine hours when en-
gine is not running, turn Engine Control switch
to Run or Auto (optional) position.
5 Engine Indicator Light
Light goes on and engine stops if engine tem-
perature exceeds 230 F (110 C) or engine
oil pressure is below 10 psi (69 kPa).
.Normal engine temperature is 180 - 2035
F (82 - 955 C). Normal oil pressure is 30
- 60 psi (207 - 414 kPa).
Y Do not run engine until trouble is
fixed.
Weld Controls
6 Remote Control Receptacle
Use receptacle to connect remote controls
and wire feeders.
When a remote control is connected to the
Remote receptacle, the Auto Sense Remote
feature automatically switches voltage/am-
perage control to the remote control (see Sec-
tion 4-9).
If no remote control is connected to the Re-
mote receptacle, the front panel Voltage/Am-
perage control adjusts voltage and amper-
age.
.If a remote device connected to Remote
Receptacle RC14 is faulty or is discon-
nected, the meters display Help 25 (see
Section 8-12). Clear fault by stopping
and restarting the unit or by turning Pro-
cess/Contactor switch to another posi-
tion.
See Section 5-3 for Process/Contactor
switch information.
8 Voltage/Amperage Control
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage.
With Process/Contactor switch in any Wire
(MIG) position, use control to adjust voltage.
With Process/Contactor in any Stick or TIG
remote control receptacle, high output limit is
set by the front panel Voltage/Amperage con-
trol. The remote control adjusts output be-
tween minimum and the high limit set by the
front panel control.
With Process/Contactor switch in any MIG
remote control receptacle, the front panel
Voltage/Amperage control has no effect on
weld output.
Weld Meters
.Weld meters also work in combination to
display troubleshooting help codes (see
Section 8-12).
9 DC Voltmeter
Voltmeter displays preset voltage (MIG weld-
ing) with contactor off, and actual output volt-
age with the contactor on. Voltmeter displays
voltage at the weld output terminals, but not
necessarily the welding arc due to resistance
of cable and connections.
To set voltage, turn contactor off and turn Pro-
cess/Contactor switch to Wire position. Turn
V/A control until desired voltage is displayed
on Voltmeter. When welding is finished, volt-
meter displays weld voltage and then defaults
to preset voltage.
10 DC Ammeter
Ammeter displays preset amperage (Stick
and TIG only) when not welding, and actual
output amperage when welding.
To set amperage, turn Process/Contactor
switch to Stick or TIG position. Turn V/A con-
trol until desired amperage is displayed on
Ammeter. When welding is finished, ammeter
displays weld amperage and then defaults to
preset amperage.
6-3. Process/Contactor Switch On CC/CV Models
Y Weld output terminals are ener-
gized when Process/Contactor
switch is in a Weld Terminals Al-
ways On position and the engine
is running.
Use switch to select weld process and
weld output on/off control (see table be-
low).
Place switch in Remote On/Off Switch
Required positions to turn weld output on
and off with a device connected to the
Remote 14 receptacle.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use Stick mode for air carbon arc
(CAC-A) cutting and gouging.
When switch is in Stick mode, select one
of four arc drive (dig) settings to provide
additional amperage during low voltage
(short arc length) conditions and prevent
sticking electrodes. Turn control from A
to D to increase arc drive (dig) from min
to max.
Use the Lift-Arc TIG mode for TIG
(GTAW) welding using the Lift-Arc TIG
starting procedure (see Section 5-4).
1
226 386-B / 804 009-C
Process/Contactor Switch Settings
Switch Setting Process Output On/Off Control Engine Auto Idle (Optional) Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)
Remote On/Off Switch Re-
quired TIG HF Required Or
Scratch Start
GTAW With HF Unit, Pulsing
Device, Or Remote Control
Required Stick
Stick (SMAW) With Remote On/Off At Remote 14 Receptacle Active
Required CV Feeder
Using Remote
MIG (GMAW)
w/Constant Speed Feeder
Weld Terminals Always On
Wire
MIG (GMAW)
w/Voltage Sensing Feeder
Stick
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting
And Gouging
TIG Lift-Arc
TIG Lift-Arc (GTAW) Electrode Hot Active
6-4. Lift-Arc Start Procedure
Lift-Arc t TIG
With Lift-Arct TIG selected, start
arc as follows:
1 TIG Electrode
2 Workpiece
Turn gas on. Touch tungsten
electrode to workpiece at weld start
point. Hold electrode to
workpiece for 1-2 seconds, and
slowly lift electrode. Arc is formed
when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece
without overheating, sticking, or be-
ing contaminated.
Application:
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to
replace the scratch method.
1
1 2
Seconds
Touch
Do NOT Strike Like A Match!
2
Lift-Arc Start Method
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
6-5. Remote Voltage/Amperage Control
1 Remote 14 Receptacle RC14
Connect optional remote control to RC14 (see
Section 4-9).
.When a remote control is connected to the
Remote receptacle, the Auto Sense Re-
mote feature automatically switches volt-
age/amperage control to the remote con-
trol. When a device is connected to the Re-
mote receptacle, remote voltage/amper-
age control is always available regardless
of the position of the Process/Contactor
switch.
0774 / Ref.226 386-B / 804 009-C
Adjust Optional Remote
Control to 100%
Set V/A Control
To Desired Maximum
Weld Output Using Weld
Meters
Set TIG or STICK Process
In Example:
Min = 20 A DC
Max = 205 A DC
Max (205 A DC)
Min (20 A DC)
Connect Remote
Control To Remote
Receptacle RC14
1
Control to desired
weld output
Weld meters will always
show the combined main
and remote control setting
and machine welds at
nominal output setting of
the meter.
Weld meters show preset
output when not welding.
Set WIRE Process
Connect Remote
Control To Remote
Receptacle RC14
Control to desired
weld output
SECTION 7 OPERATING AUXILIARY EQUIPMENT
7-1. CC Model Auxiliary Power Receptacles
Ref. 217 359-A
1 220V 16 A AC Receptalce RC12
2 110V 20 A AC Receptacle GFCI1
If a ground fault is detected, GFCI Reset
button pops out and receptacle does not
work. Check for faulty equipment plugged in
receptacle. Press button to reset GFCI re-
ceptacle.
3 Supplementary Protector CB5
CB5 protects GFCI1 from overload. If a
supplementary protector opens, the recep-
tacle does not work. Press button to reset.
4 Earth Leakage Circuit Breaker ELCB1
5 Earth Leakage Circuit Breaker ELCB2
ELCB1 protects RC12 and ELCB2 protects
RC11 from overload and earth leakage
fault. If a circuit breaker opens, the recep-
tacle does not work. Place switch in On
position to reset circuit breaker.
6 220V 32A AC Receptacle RC11
Receptacles GFCI1, RC11, and RC12
supply 60 Hz single-phase power at weld/
power speed.
Maximum combined output of all recep-
tacles is 10 kVa/kW.
.At least once a month, run engine at
weld/power speed and press test but-
ton to verify ELCB1, ELCB2, and GFCI
are working properly.
.Generator power decreases as weld
output increases.
1 2 3 4 5 6
7-2. CC/CV Model Auxiliary Power Receptacles
226 386
1 110 V 16 A AC Receptacle RC12
2 Earth Leakage Circuit Breaker
ELCB1
3 Earth Leakage Circuit Breaker
ELCB2
ELCB1 protects RC12 and ELCB2 protects
RC11 from overload and earth leakage
fault. If a circuit breaker opens, the recep-
tacle does not work. Place switch in On
position to reset circuit breaker.
.At least once a month, run engine at
weld/power speed and press test but-
ton to verify ELCB1 and ELCB2 are
working.
4 110 V 32 A AC Receptacle RC11
RC11 and RC12 supply 60 Hz single-phase
power at weld/power speed.
.Generator power decreases as weld
output increases.
Combined output of all receptacles is limit-
ed to the 10 kVA/kw rating of the generator.
1
2 3
4
SECTION 8 MAINTENANCE
8-1. Maintenance Label

8-2. Routine Maintenance
Y Stop engine before maintaining.
.See Engine Manual and Maintenance Label
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
Recycle engine
fluids.
n = Check Z = Change ~ = Clean l = Replace
* To be done by Factory Authorized Service Agent
Reference
Every
8
Hours
Section 4-6,
8-10
n Coolant Level n Fuel Level n Oil Level ~ Oil, Fuel Spills
Every
50
Hours
Section 8-5
~ Air Cleaner Element ~ Weld Terminals
Every
100
Hours
~ Battery Terminals n Air Cleaner Hoses
Every
250
Hours
1/2 in.
(13 mm)
Engine
Manual,
Section 8-6,
8-10
l Unreadable Labels n Fan Belt Tension Z Oil Z Oil Filter n~Spark Arrestor
Every
500
Hours
nl Weld Cables Z FuelFilter Z Inline Fuel Filter
Every
1000
Hours
OR
SLUDGE
FUEL
Section 4-6,
8-4, 8-7,
8-10, and
Engine
Manual
nRadiator Fluid Level ~ Inside Unit nValve Clearance* ~ Drain Sludge
n~ Slip Rings*
nl Brushes*
Every
2000
Hours
~ Injectors*
8-3. Caterpillar Customer Assistance
Service
When a problem arises concerning the op-
eration or service of the engine, the prob-
lem will normally be managed by the dealer
in your area.
Your satisfaction is a primary concern to
Caterpillar and to Caterpillar dealers. If you
have a problem that has not been handled
to your complete satisfaction, follow these
steps:
1 Discuss your problem with a manager
from the dealership.
2 If your problem cannot be resolved at
the dealer level without additional
assistance, call a Field Service
Coordinator at 1-800-447-4986.
3 If your needs still have not been met,
submit the matter in writing to:
Caterpillar Inc.
Manager, Customer Service,
Engine Division
Mossville Bldg A
P.O. Box 600
Peoria, IL 61552-0600
Please follow the above steps in sequence
if a problem arises.
Website Address
www.caterpillar.com
Altitude
Contact the Caterpillar applications depart-
ment for information on the effect of ambient
conditions on Caterpillar 3024 engines.
8-4. Checking Generator Brushes
Ref 226 386-B / S0233A
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
5/16 in. (8 mm)
Minimum Length
9/16 in. (14.3 mm)
New Length
Replace
Damaged Brushes
8-5. Servicing Air Cleaner
Y Stop engine.
Y Do not run engine without air
cleaner or with dirty element. En-
gine damage caused by using a
damaged element is not covered
by the warranty.
.The air cleaner primary element can
be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.
If you decide to clean the primary ele-
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
2 Safety Element (Optional)
3 Primary Element
4 Dust Cap
5 Dust Ejector
To clean air filter:
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
Y Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
Blow Inspect
4 1 3
5
Keep nozzle
2 in (51 mm)
from element.
2
aircleaner1 2/01 ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 226 386-B
Optional
8-6. Inspecting And Cleaning Spark Arrestor Muffler
803 582-F / Ref. 226 386-B
1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3 Exhaust Pipe
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
Reinstall cleanout plug.
Tools Needed:
3/8 in
1
2
3
8-7. Servicing Engine Cooling System
804 009C / Ref 226 386-B
1 Radiator Draincock
2 Radiator Cap Cover
Change coolant according to engine
manual. Add coolant according to Sec-
tion 4-6).
Run engine until engine reaches normal
operating temperature. Check coolant
level in recovery tank. Add coolant if nec-
essary.
After engine cools, check coolant level
again and add coolant if necessary.
1
2
8-8. Adjusting Engine Speed On Standard Models
804 009C
3
1
2
RPM (Hz)
Engine Speed
(No Load)
Weld/Power
1850 (61.7)
Maximum
Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine
speed with tachometer or frequen-
cy meter. See table for proper no
load speed. If necessary, adjust
speed as follows:
Start engine and run until warm.
Turn Process/Contactor switch to
position.
1 Lock Nut
2 Adjustment Screw
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
.Do not set engine speed higher
than specified. Tampering with
adjustments other than shown
may affect engine warranty.
3 Engine Stop Lever
Y Stop engine.
Close door.
Tools Needed:
8-9. Adjusting Engine Speed On Models With Automatic Idle (Optional)
804 492-A / Ref. 803 563-E
1880 rpm max
(62.6 Hz)
1250 rpm
(41.6 Hz)
Engine Speed
(No Load)
After tuning engine, check engine speed
with tachometer or frequency meter. See
table for proper no load speed. If neces-
sary, adjust speed as follows:
Start engine and run until warm.
Turn Process/Contactor switch to Stick
Weld Terminals Always On position.
Idle Speed Adjustment
1 Throttle Rod/Plunger
2 Locknut
Loosen locknut. Place Engine Control
switch in Auto position.
Turn throttle rod and plunger until engine
runs at idle speed. Tighten locknut.
.Be sure solenoid plunger pulls all the
way in (bottoms) when energized.
.If necessary, move linkage to other
hole in bracket or move cotter pin to
other hole in throttle arm to set idle
speed correctly.
Weld/Power Speed Adjustment
.Weld/power speed adjustment must
be done by the engine manufactur-
ers factory authorized service
agent.
Tampering with adjustments other
than shown may affect engine war-
ranty.
Y Stop engine.
2
1
Tools Needed:
8-10. Servicing Fuel And Lubrication Systems
Ref 226 386-B / 804 009C
1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary (Canister) Fuel Filter
5 Secondary (In-Line) Fuel
Filter
6 Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve
through hole in base. See engine
manual and engine maintenance
label for oil/filter change in-
formation.
To replace primary (canister) fuel
filter:
Turn filter counterclockwise. Re-
move filter.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new fil-
ter. Install new filter and turn clock-
wise.
Inspect fuel lines, and replace if
cracked or worn.
To drain water from fuel system:
See engine manual.
To replace secondary (in-line)
fuel filter:
Note direction of fuel flow as indi-
cated by arrow on side of filter. Re-
move fuel line clamps and discon-
nect fuel lines from fuel filter. Re-
place filter, reconnect fuel lines, and
reinstall clamps.
To drain sludge from fuel tank:
Y Beware of fire. Do not smoke
and keep sparks and flames
away from drained fuel. Dis-
pose of drained fuel in an en-
vironmentally-safe manner.
Do not leave unit unattended
while draining fuel tank.
Y Properly lift unit and secure
in a level position. Use ade-
quate blocks or stands to
support unit while draining
fuel tank.
Attach 1/2 ID hose to drain valve.
Put metal container under drain,
and use screwdriver to open
sludge drain valve. Close valve
when sludge has drained. Remove
hose.
Close door.
Y After servicing, start engine
and check for fuel leaks.
Stop engine, tighten connec-
tions as necessary, and wipe
up spilled fuel.
Tools Needed:
3
5
2
4
1
6
8-11. Overload Protection
Ref. 226 386-B / 803 566-E / 804 009-C
5
3
4
1
Y Stop engine.
1 Fuse F1
F1 protects the stator exciter wind-
ing from overload. If F1 opens, weld
and generator power is low or stops
entirely.
If F1 continues to open, check volt-
age regulator board PC3.
.If PC3 senses an overload con-
dition (shorted rotor), it protects
itself by stopping weld output.
Check rotor and brushes before
replacing PC3.
2 Circuit Breaker CB1 (Not
Shown)
CB1 protects the engine battery cir-
cuit. If CB1 opens, the engine will not
crank. CB1 automatically resets
when the fault is corrected. If CB1
continues to open, check fuel sole-
noid FS1, the fuel pump, throttle so-
lenoid TS1, integrated rectifier SR1,
engine alternator, glow plug, and cir-
cuit boards PC2, PC3, and PC5.
CB2 protects the engine wiring har-
ness. If CB2 opens, the engine will
not crank. Press button to reset If
CB2 continues to open, check fuel
solenoid FS1, the fuel pump, throttle
solenoid TS1, integrated rectifier
SR1, and circuit board PC5 and Fuel
Gauge/Hour Meter.
CB3 protects part of the weld control
wiring harness. If CB3 opens, weld
and generator power output stops. If
CB3 continues to open, check circuit
boards PC1, PC2, and PC3.
CB8 protects the 24 volt ac output to
remote receptacle RC14. If CB8
opens, 24 volt output to RC14 stops.
If CB8 continues to open, check re-
mote controls connected to Remote
receptacle RC14, and circuit board
PC6.
8-12. Optional Voltmeter/Ammeter Help Displays
2
1
HL.P 22
HL.P 23
HL.P 24
HL.P 25
HL.P 20
HL.P 21
6
5
4
3
Ref. 804 009-C
Use the Voltmeter/Ammeter help
displays to diagnose and correct
fault conditions.
.To reset help displays, stop
unit and then restart. See item
6 below to reset Help 25 dis-
play.
1 Help 20 Display
Indicates a failure of meter display
module PC2, or the wiring between
PC2 and main control module PC1.
If this display is shown, check PC1,
PC2, and the wiring between PC1
and PC2.
2 Help 21 Display
Indicates thermistor TH1 on the
main rectifier heat sink has failed.
If this display is shown, check TH1,
and the wiring between TH1 and
PC1.
3 Help 22 Display
Indicates the rectifier heat sink has
overheated. If this display is shown,
check generator cooling system
and/or reduce duty cycle. Keep en-
gine access door closed when run-
ning to maintain proper cooling air
flow past rectifier. Allow unit to cool
before restarting.
4 Help 23 Display
Indicates one of the rectifier output
SCRs has failed. If this display is
shown, check the rectifier SCRs.
5 Help 24 Display
Verify engine speed is correct by
checking frequency at 115 volt ac
duplex receptacle (should be
approximately 62 Hertz with Engine
Control switch in the Run position).
If engine speed is correct and weld
open circuit voltage (OCV) is too
high (above 41 volts dc), check
main control module PC1.
6 Help 25 Display
Indicates a remote device con-
nected to Remote Receptacle
RC14 may be faulty. Help 25 is also
displayed whenever a remote de-
vice has been connected to RC14
and then disconnected. Clear fault
by stopping and restarting the unit
or by turning Process/Contactor
switch to another position. If prob-
lem continues, check the remote
device, filter board PC6, and main
control module PC1.
If no remote control device is
plugged in to Remote receptacle
RC14 and the corrective action
above has been followed, discon-
nect filter board PC6. If the help
code is still displayed, main control
module PC1 may be at fault. If the
help code clears, replace PC6.
.When a help code is displayed
normally weld output has
stopped but generator power out-
put may be okay. Auxiliary power
must be available and correct be-
fore continuing. If auxiliary output
is not correct, disregard help
codes until auxiliary power prob-
lem is corrected. If both weld out-
put and auxiliary power are not
available, see Section 10-7 for
module testing information.
SECTION 9 THEORY OF OPERATION
1 Engine
Supplies force to turn revolving fields.
2 Revolving Fields (Rotor)
Turn at 1885 rpm maximum for weld and
power. The speed and excitation current
of the field coils determine voltages in
stator windings.
3 Stator Windings
Supply power to exciter, generator pow-
er, and weld circuits.
4 Fuse F1
Protects exciter windings from over-
load.
5 Voltage Regulator Board PC3
Changes ac output of stator windings to
dc to supply excitation current to the ex-
citer revolving field.
Controls field current in response to
changes in output load.
If PC3 senses an overload condition
(shorted rotor), it protects itself by stop-
ping excitation current (weld and gener-
ator power output stops).
6 Circuit Breakers CB4, CB5, and
CB6
Protect AC receptacles from overload.
7 AC Receptacles GFCI1, GFCI2
and RC11
Provide connection points and power for
auxiliary equipment.
8 Circuit Breakers CB7 and CB8
Provide overload protection for 24 and
115 volts ac portion of Remote 14 recep-
tacle RC14.
9 Filter Board PC6/Remote Recep-
tacle RC14
PC6 protects unit from high frequency,
and RC14 connects remote amperage/
voltage and contactor controls to unit.
When a remote control is connected to
the Remote receptacle, the Auto Sense
Remote feature automatically switches
voltage/amperagecontrol to the remote
control.
10 Voltage/Amperage Control R2
Adjusts weld output amperage or volt-
age level.
11 Process/Contactor Switch R1
Selects weld process and weld output
on/off control.
Circuit
8
8
Breaker
CB7
9
Control
Board
PC1
115 VAC
24 VAC
+10 VDC Output
Command Voltage
12
3
Exciter
Stator Windings
Generator Power
W
e
l
d
Revolving
Fields
(Rotor)
Engine
Voltage
Regulator
Board PC3
5
2 1 3
Current
Feedback
Circuit
Breakers
6
CB4, CB5, CB6
7
4
Fuse F1
AC
Receptacles
GFCI1, GFCI2,
RC11
Circuit
Breaker
CB8
Filter Board
PC6/Remote
Receptacle
RC14
12 Control Board PC1
Controls weld output by changing
main rectifier SCR gate pulses
(conduction times) after comparing
amperage (CC) or voltage (CV)
feedback to selected voltage/am-
perage signal.
13 Thermostat TH1
Thermostat opens and stops all
weld output if unit overheats.
14 Meter Board PC2
Displays preset and actual (rectified
and filtered) values of the weld volt-
age and amperage.
15 Main Rectifier
Changes ac weld current to dc.
Works with PC1 (item 12) to con-
trols weld output by changing recti-
fier SCR gate pulses (conduction
times) after comparing voltage (CV)
or amperage (CC) feedback to se-
lected voltage or amperage signal.
16 Burden Resistor R3
Provides a path for a minimum SCR
holding current to flow.
17 Hall Device HD1
Provides current feedback signal to
PC1.
18 Stabilizer Z1
Smooths (filters) weld output
current.
19 Capacitor Bank C10
Filters the dc output voltage of main
rectifier.
20 Work (), CC, And CV Weld
Output Terminals
Provide weld output and allow
manual changing of output polarity.
AC Or DC Control Circuits
Weld Current Circuit
External Circuits
Thermostat
13
TH1
SCR
Gating
Signals
17
Hall Device
HD1
16
18
Current
Feedback
Stabilizer
Z1
20
20
Electrode
Work
19
Capacitor
Bank C10
20
CC or CV
Voltage
Feedback
Main
Rectifier
15
3 Power
CV Weld
Output
Terminal
CC Weld
Output
Terminal
Work () Weld
Output
Terminal
11
Process/
Contactor
Switch R1
14
Meter
Board PC2
10
Voltage/
Amperage
Control R2
CC
CV
Burden
Resistor R3
.CC/CV Model Shown. CC only model does
not have capacitor bank C10 or CV weld out-
put terminal.
TM-4435 Page 42 Big Blue 400CX
SECTION 10 TROUBLESHOOTING
10-1. Troubleshooting Tables
.See Section 10-2 for test points and
values and Section 14 and following
for parts location.
.Use MILLER Testing Booklet (Part
No. 150 853) when servicing this
unit.
Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see
Section 8-12).
Note
A. Welding
Trouble Remedy
No weld output; generator power output
okay at ac receptacles.
Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
On/Off Switch Required position and turn remote contactor on (see Section 4-9).
Reset supplementary protector CB8 (see Section 8-11). Check for faulty remote device connected to
RC14.
Check and secure connections to Remote Control receptacle RC14 (see Section 4-9).
Check resistance and connections of Voltage/Amperage Adjust control R2; R2 is 1000 ohms 10%.
Replace R2 if necessary.
Check reactor Z1 for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace Z1 if necessary.
Check Voltmeter/Ammeter help displays (see Section 8-12).
No weld output, or generator power out-
put at ac receptacles.
Disconnect equipment from generator power receptacles during start-up.
Reset supplementary protector CB3 (see Section 8-11).
Check fuse F1, and replace if open (see Section 8-11). If F1 is open, check the voltage regulator board
PC3. If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check
rotor and brushes before replacing PC3.
Clean slip rings, and install new brushes if necessary (see Section 10-15).
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if nec-
essary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
Determine if main control board PC1 or voltage regulator board PC3 is causing the lack of output (see
Section 10-7).
Check voltage regulator board PC3 and connections, and replace PC3 if necessary (see Section 10-10).
If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check rotor
and brushes before replacing PC3.
Check main control board PC1 and connections, and replace PC1 if necessary (see Sections 10-8 and
10-9).
Erratic weld output. Check and tighten connections inside and outside unit. Be sure connection to work piece is clean and
tight.
Be sure weld cables have no nicks or gouges and no kinks.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Trouble Remedy
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if
necessary.
High weld output. Repair or replace remote control device.
Check hall device HD1, and replace if necessary (see Section 10-2).
10-9).
Low weld output. Check engine speed, and adjust if necessary (see Section 8-8 or 8-9).
Increase Voltage/Amperage Adjust control R2 setting.
Check fuse F1, and replace if open (see Section 8-11).
Repair or replace remote control device.
essary.
Low open-circuit voltage. Check engine speed, and adjust if necessary (see Section 8-8 or 8-9).
10-9)..
Check SCRs in main rectifier, and replace if necessary (see Section 11-4). If any SCRs are re-
placed, check capacitors C1 through C9 for a short or open, and check for proper connections. Re-
place C1 through C9 if necessary.
No remote fine amperage control. Repair or replace remote control device.
Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 4-9).
No 24 volt ac output at Remote recep-
tacle RC14.
Reset circuit breaker CB8 (24 volt) (see Section 8-11).
Check filter board PC6, and replace if necessary.
B. Generator Power
Trouble Remedy
No generator power output at ac recep-
tacles; weld output okay.
Reset receptacle supplementary protectors (see Section 7-1).
Check resistance of generator power windings between leads 84 and 99. Replace stator if necessary.
No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
PC3 (see Section 10-10). If PC3 senses an overload condition (shorted rotor), it protects itself by stop-
ping weld output. Check rotor and brushes before replacing PC3.
Reset circuit breaker CB3 (see Section 8-11).
Clean slip rings, and install new brushes if necessary (see Section 10-15).
essary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if
necessary.
Determine if main control board PC1 or voltage regulator board PC3 is causing the lack of output (see
Section 10-7).
Trouble Remedy
10-9).
High output at generator power ac
receptacles.
Check connections at isolation transformer Ti. Check T1 continuity and replace if necessary.
Voltage feedback signal not present. Check and tighten/repair connections.
Low output at generator power ac
receptacles.
Check engine speed, and adjust if necessary (see Section 8-8 or 8-9).
PC3 (see Section 10-10). If PC3 senses an overload condition (shorted rotor), it protects itself by stop-
ping weld output. Check rotor and brushes before replacing PC3.
C. Engine
Trouble Remedy
Engine will not crank. Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-11).
Check engine wiring harness and components.
Reset supplementary protector CB2 (see Section 8-11).
Check engine wiring harness plug connections.
Check continuity of Engine Control switch S1, and replace if necessary.
Check Fuel Gauge/Hourmeter FUEL HM and connections, and replace FUEL/HM if necessary.
Check control relay CR1 for proper coil voltage and connections. Check continuity of coil and condition
of contacts. Replace CR1 if necessary.
Engine cranks but does not start. Check fuel level.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coil. Replace
FS1 if necessary.
Check fuel pump according to engine manual.
Air in fuel system. See engine manual.
Engine hard to start in cold weather. Use Preheat switch (see Section 5-2).
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 8-1).
Check continuity of Preheat switch S4, and replace if necessary.
Check glow plug for proper operation, and replace if necessary.
Engine suddenly stops. Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 4-6 ).
Reset circuit breaker CB1 and/or CB2 (see Section 8-11). Check engine alternator, engine harness,
throttle solenoid TS1, fuel solenoid FS1, and the fuel pump.
Trouble Remedy
Check continuity of Engine Control switch S1, and replace if necessary.
Check integrated rectifier SR2, and replace if necessary.
Check fuel solenoid FS1 for proper coil voltage and connections. Check continuity of coil. Replace
FS1 if necessary.
Check fuel pump according to engine manual.
Check engine wiring harness and plug connections.
See engine manual.
Engine slowly stopped and cannot be
restarted.
Check fuel level.
Check engine air and fuel filters (see Sections 8-5 and 8-10).
See engine manual.
Battery discharges between uses. Turn Engine Control switch S1 off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine idles, but does not come up to
weld speed (units with idle option only).
Check for obstructed throttle solenoid TS1
Check idle module PC5, and replace if necessary.
Check current transformer CT1 for continuity and proper connections. Replace CT1 if necessary.
Engine does not run at idle speed
(units with idle option only).
Check for obstructed throttle solenoid TS1.
Check idle module PC5, and replace if necessary.
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine according to run-in procedure (see Section 13).
Notes
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3)
V3,R3
I1
Glow plug
relay CR3
Starter control
relay CR2
V4,
V5,R5
R4
Engine
control
relay CR1
See Section 10-10
for PC3 data
V2,R2
V6,R6
V7,
R7
R10
V8,
R8
V10
R9
V21
V22
V23
V24
E
See Section
10-12 for PC2
data
V1,R1
V1,R1
V1,R1
V1,R1
V9
V25,
R12
226 566-B
See Section 10-4
for waveforms
A,B,C,D,E
See Section
10-5 for
PC6 data
See Section
4-9 for RC14
information
V11, R11
V12 V13 V14
V15,
A,C
V18
E
E
E E
E
V19
V20
V17
E
E
E
V16,
B,D
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2)
Resistance Values
a) Tolerance 10% unless specified
b) Condition 70F (21C); cold
machine (no warm-up)
c) Wiring Connections see Section
12
d) Stop engine before checking
resistance
R1 thru R6 Less than 1 ohm
R7 22 ohms
R8 14.2 ohms
R9 Empty fuel tank: 250 ohms
Full tank: 0 ohms
R10 30 Kohms cold, drops as
unit heats up
R11 Increases in 1 Kohm
increments up to 11 Kohms,
then resets to zero
R12 14.2 ohms
Test Equipment Needed:
Amperage Readings
b) Condition 70F (21C); cold
machine (no warm-up); no load;
weld/power rpm unless noted
c) Process/Contactor switch R1 in
(Dig-B) position unless noted
I1 3.1 amps dc
4.6 amps at 20 volt, 200 amp load
Voltage Readings
b) Condition 70F (21C); cold machine
(no warm-up); no load; weld/power rpm
unless noted
c) Reference single arrow: reference to
circuit common (lead 42); double
arrow: reference to points indicated
d) Process/Contactor switch R1 in Weld
Terminals Always On Stick (Dig-B)
position unless noted
e) Wiring Connections see Section 12
V1 49 60 volts ac
V2 158 volts ac
V3 24 volts ac
V4 46 volts ac
V5 46 volts ac
V6 46 volts ac
V7 + 61 volts dc
V8 +12 volts dc
V9 +12 volts dc
V10 +12 volts dc
V11 0 to +5 volts dc from Weld Terminals
Always OnWire position to RemoteWire
position of Process Contactor switch R1 (in
0.45 volt increments)
V12 +5 volts dc
V13 0 to +5 volts dc from min to max of
Voltage/Amperage control R2
V14 +5 volts dc
V15 +41 volts dc with Process/Contactor switch
R1 in Weld Terminals Always On Stick
position; +20 volts dc with R1 in TIG
position
V16 14 to +40 volts dc with Process/Contactor
switch R1 in Weld Terminals Always
OnWire position
V17 Circuit common
V18 1 volt dc per 100 amperes of weld output
V19 15 volts dc
V20 +15 volts dc
V21 +12 volts dc
V22 +12 volts dc input with Engine Control
switch S1 in Start position
V23 +12 volts dc input with Engine Control
switch S1 in Start or Run position
V24 Ground path for CR1:
Normal operation: 0 volts dc
Fault shutdown: +12 volts dc
V25 +12 volts dc
10-4. Waveforms For Sections 10-2
2 ms 50 V
A. CC/DC Open-Circuit Voltage, Process/Con-
tactor Switch R1 In Weld Terminals Always On
Stick (Dig B) Position, Voltage/Amperage
Control R2 At Max
2 ms 20 V
B. CV/DC Open-Circuit Voltage, Process/Con-
tactor Switch R1 In Weld Terminals Always
On Wire Position, Voltage/Amperage Con-
trol R2 At Max
gnd
gnd
.The waveforms represent the output of the welding power source. When operating properly, the power source waveforms match those shown.
E. SCR Gate Pulses w/Respect To Cathode At No
Load, Process/Contactor Switch R1 In Weld
Terminals Always On Stick (Dig B) Position,
Voltage/Amperage Control R2 At Max
2 ms 50 V
gnd
C. CC/DC Output, 30 Volts DC, 250 Amperes, Pro-
cess/Contactor Switch R1 In Weld Terminals
Always On Stick (Dig B) Position, (Resistive
Load)
D. CV/DC Output, 30 Volts DC, 250 Amperes, Pro-
cess/Contactor Switch R1 In Weld Terminals
Always On Wire Position, (Resistive Load)
2 ms 20 V
gnd
5 ms 2 V
gnd
10-5. Filter Board PC6 Testing Information
Ref. 804 492A / 217 008
Y Stop engine.
See Section 10-6 for specific val-
ues during testing. Voltage read-
ings tolerance 10%.
1 Filter Board PC6
2 Receptacle RC2
1
2
10-6. Filter Board PC6 Test Point Values
PC6 Voltage Readings
a) Tolerance 10% unless
specified
b) Reference to circuit common
(lead 42) unless noted
c) Condition no load; weld/pow-
er rpm unless noted
d) Process/Contactor switch S6
in Weld Terminals Always On
Stick position
Receptacle Pin Value
RC2 1 24 volt ac input with respect to pin RC2-5
2 Not used on this model
3 115 volts ac input with respect to pin RC2-5
4 Voltage feedback: 1 volt dc per 10 arc volts
5 Circuit common for 24 and 115 volt ac contactor control circuits
6 Command reference: +10 volt dc input
7 Contactor control circuit: 24 volt ac input with respect to pin RC2-5 and closure on RC14 between
pins A and B
8 Command common
9 Remote command signal input: 0 to +10 volts dc input from min to max of remote voltage/amperage
control
10 Current feedback: 1 volt dc per 100 arc amperes
10-7. Module Testing Information
Ref. 804 492-A
If there is no weld output and no
auxiliary power output, use this
testing information to determine
which circuit board module may be
at fault.
1 Main Control Board PC1
2 Plug PLG6
3 Jumper Wires
Locate 30pin plug PLG6 and dis-
connect from PC1 module. Install
jumper wires at the following pins:
G3 (Lead No. 117) to H3 (Lead No.
113)
D2 (Lead No. 107) to J3 (Lead No.
130)
Start engine with these jumpers
installed and check for auxiliary
power.
If auxiliary power is present, PC1
could be at fault. Use Sections 10-8
and 10-9 to troubleshoot PC1.
If auxiliary power is not present,
Voltage Regulator board PC3 could
be at fault. Be sure PC3 is supply-
ing the following voltages at PC1
module:
4 Plug PLG7
Check for +14 volts dc at PLG7 pin
E1 (lead no. 120)
Check for +15 volts dc at PLG6 pin
E3 (lead no. 109)
Check for 15 volts dc at PLG6 pin
F3 (lead no. 106).
Use Sections 10-10 and 10-11 to
troubleshoot PC3.
Remove jumper wires before con-
tinuing troubleshooting.
1
2
3
4
10-8. Main Control Board PC1 Testing Information
803 930A
Y Stop engine.
ings tolerance 10%.
1 Main Control Board PC1
2 Plug PLG6
3 Plug PLG7
4 Plug PLG11
.If no weld output and no auxilia-
ry power are available, see
Section 10-7 for module testing
information before trouble-
shooting PC1.
1
4
2
3
10-9. Main Control Board PC1 Test Point Values
specified
er rpm unless noted
d) Process/Contactor switch R1
Stick position
PLG6 A1 Serial data line
A2 +5 volts dc output
A3 CV weld feedback with respect to pin PLG6-B3: same as OCV or load voltage
B2 Command signal input: 0 to +5 volts dc input from min to max of Voltage/Amperage control R2
B3 Voltage feedback reference
C1 Serial data line
C2 Circuit common for Voltage/Amperage control R2
C3 CC weld feedback with respect to pin PLG6-B3; same as OCV or load voltage
D2 Frequency to voltage signal: +10 volts dc input at 1860 rpm
D3 Not used on this model
E2 Synchronization signal
E3 Power supply input: +15 volts dc
F1 Not used on this model
F2 Voltage feedback: 1 volt dc per 10 arc volts
F3 Power supply input: 15 volts dc
G1 Not used on this model
G2 Command reference: +10 volt dc input
G3 Shutoff command output (field current); normal condition: 0 volts dc, fault condition: 0.7 volts dc
H1 Not used on this model
H2 Remote command signal input: 0 to +10 volts dc input from min to max of remote voltage/amperage
control
H3 Circuit common
J1 Not used on this model
J3 +10 volts dc output
K1 +5 volts dc output
K3 24 volts ac input
PLG7 A1 0 to +5 volts dc from Weld Terminals Always OnWire position to RemoteWire position of Process
Contactor switch R1 (in 0.45 volt increments)
A2 1 volt dc input per 100 amperes of weld output with respect to pin PLG7-C2
B1 Circuit common for Process/Contactor switch R1
B2 +15 volts dc output with respect to pin PLG7-C2
B3 Contactor control circuit: 24 volt ac input with respect to circuit common and closure on RC14 be-
tween pins A and B
C1 +5 volts dc output
C2 Circuit common
C3 SCR fault signal; +5 volts dc output if any SCR fails
Receptacle Value Pin
D1 +2 volts dc input at 77 F
D2 15 volts dc with respect to pin PLG7-C2
E1 +13 volts dc input
F1 Command common
F2 Weld idle control signal: 0 volts dc output when welding; 3.5 volts dc input when not welding
F3 Current feedback: 0 volts dc input per 100 arc amperes
PLG11 A1 Gate Pulse to SCR1 with respect to pin PLG11-A2
A2 Reference for gate pulse to SCR1
A3 Gate Pulse to SCR2 with respect to pin PLG11-B3
B1 Reference for gate pulse to SCR3
B2 Gate Pulse to SCR3 with respect to pin PLG11-B1
B3 Gate Pulse to SCR2 with respect to pin PLG11-A3
C1 Gate Pulse to SCR4 with respect to pin PLG11-C2
C2 Reference for gate pulse to SCR4
C3 Reference for gate pulse to SCR5
D1 Reference for gate pulse to SCR6
D2 Gate Pulse to SCR6 with respect to pin PLG11-D1
D3 Gate Pulse to SCR5 with respect to pin PLG11-C3
E1 Gate Pulse to SCR7 with respect to pin PLG11-E2
E2 Reference for gate pulse to SCR7
E3 Gate Pulse to SCR8 with respect to pin PLG11-F3
F1 Reference for gate pulse to SCR9
F2 Gate Pulse to SCR9 with respect to pin PLG11-F1
F3 Reference for gate pulse to SCR8
10-10. Voltage Regulator Board PC3 Testing Information
803 930A
Y Stop engine.
ings tolerance 10%.
1 Voltage Regulator Board PC3
2 Receptacle RC1
3 Receptacle RC2
.If no weld output and no auxilia-
ry power are available, see
Section 10-7 for module testing
information before trouble-
shooting PC3.
1
2
3
10-11. Voltage Regulator Board PC3 Test Point Values
specified
er rpm unless noted
Stick position
RC1 1 14 volts dc input with respect to pin RC1-3
2 +13 volts dc output
3 Circuit common
4 Circuit common
5 Power supply output: +15 volts dc
6 Power supply output: 15 volts dc
7 +10 volts dc input
8 Shutoff command input (field current): normal condition: 0 volts dc, fault condition: 0.7 volts dc
9 Frequency to voltage signal: +10 volts dc output at 1860 rpm
10 SCR fault signal; +5 volts dc input if SCR fails
11 Synchronization signal
12 Not used
RC2 1 120 volts ac input with respect to pin RC1-3
3 Not used
4 Not used
6 +61 volts dc with respect to pin RC2-7
7 +61 volts dc with respect to pin RC2-6
8 158 volts ac with respect to pin RC2-5
9 Not used
10 Not used
11 Not used
12 Not used
10-12. Meter Display Board PC2 Testing Information
804 492-A / 214 536
Y Stop engine.
ings tolerance 10%.
1 Meter Display Board PC2
1
10-13. Meter Display Board PC2 Test Point Values
specified
er rpm unless noted
Stick position
RC1 1 +12 volts dc input with respect to pin RC1-2
2 Circuit common
3 Serial data line
4 Serial data line
10-14. Idle Module PC5 Testing Information And Troubleshooting Flow Chart
J
G
B H
E
C
A
Voltage readings tolerance 10%.
1 Idle Module PC5
.Engine starts and remains at idle
speed until a power or weld load is
applied.
.Verify engine speeds are correct
before testing idle module.
1
803 566-E
Replace
idle module.
NO
NO
Connect a 100 watt light bulb to
120 volts ac duplex receptacle.
YES
Disconnect 100 watt light bulb
and meter leads.
Connect meter between
terminal C (+) and terminal E ().
0 (zero) volts dc present?
YES
Reinstall cover.
Check connections
to current
transformer.
Engine does not go to weld/power speed
(1880 rpm) under power or weld load .
terminal G and terminal E.
YES
NO
terminal J and terminal E.
Check main
control board
PC1.
0 Volts dc present?
Check control relay CR4
and throttle solenoid
TS1.
Start engine, and place Engine
Control switch S1 in Auto position.
Place Process/Contactor switch
R1 in Weld Terminals
Always On Stick position.
terminal H and terminal E.
+12 volts dc present?
NO
Check Engine
Control switch S1,
and ground con-
nection (lead 42).
YES
NO
NO
YES
YES
terminal C (+) and terminal E ().
0 (zero) volts ac present?
YES
Reinstall cover.
Replace
idle module.
Engine does not go to idle speed (1250 rpm)
with no weld or power load applied.
NO
Start engine, and place Engine
Control switch S1 in Auto position.
R1 in Weld Terminals
Always On Stick position.
Check Engine
Control switch S1,
control relay CR1,
and ground con-
nection (lead 42).
terminal G and terminal E.
Disconnect load
from generator
power receptacles.
Check current
transformer.
3.5 volts dc present?
NO
terminal J and terminal E.
Check main
control board
PC1.
About 10 volts dc present?
Check control relay CR4,
throttle solenoid TS1,
and connections.
Connect meter (DC) between
terminal H and terminal E.
NO
Check Engine
Control switch S1,
and ground con-
nection (lead 42).
Connect meter DC between
terminal B (+) and terminal E ().
YES
Minimum of 0.75 volt ac present?
10-15. Replacing Brushes And Cleaning Slip Rings
804 493-A
Tools Needed:
1 Brush Holder Bracket
Remove brush holder bracket.
Keep hardware for reinstallation.
2 Brush Holder
3 Brush With Spring
4 Brush Holder Cap
5 Brush Holder Retaining Bar
Mark and disconnect leads at caps
and remove retaining bar. Unscrew
caps and remove brushes from
bracket.
Replace brushes if damaged, or if
brush is at or near minimum length.
6 Slip Rings
Inspect slip rings. Under normal
use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as little
material as possible.
Y Stop engine.
Install brushes, caps, bar, bracket,
and brush leads. Tighten bracket
hardware.
1
5/16 in (8 mm)
Minimum Length
9/16 in (14.3 mm)
New Length
Replace
Damaged Brushes
5
2
3
4
6
10-16. Checking Unit Output After Servicing
.Also use output waveforms to
check unit output after servic-
ing (see Section 10-4).
Check engine speeds, and adjust if
necessary (see Section 8-8 or 8-9).
R1 in Weld Terminals Always Hot
Stick position.
1 AC Power Receptacles RC11
And RC12
2 Positive (+) Weld Output Ter-
minal
3 Work () Weld Output Termi-
nal
Start engine and run at weld/power
speed (1880 rpm).
Check voltage at each receptacle.
With no load applied, there should
be approximately 220 volts ac pres-
ent at RC11 and RC12.
If correct voltage is not present, re-
peat troubleshooting procedures in
Section 10-1.
Check open-circuit voltage across
weld output terminals according to
Section 10-2. If correct voltages are
not present, repeat troubleshooting
procedures in Section 10-1.
Y Stop engine.
Allow engine to cool, and then com-
plete pre-operational checks in
table.
Pre-Operational Checks
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged.
Check fuel and oil (see Section 4-7).
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.
Tools Needed: Test Equipment Needed:
1
2
3
Ref 804 009A
Big Blue 400CX TM-4435 Page 62
SECTION 11 DISASSEMBLY AND REASSEMBLY
11-1. Disassembly Of Unit
Y Stop engine and let cool. Dis-
connect battery negative ()
cable.
Use Section 10-1 to determine if trouble
is in stator, rotor, engine or combination
of these components.
1 Engine Manifold Screw
2 Generator Mounting Screws
3 Engine Mounting Screw
4 Engine Lifting Eyes
Remove side panels, covers, and
doors. Retain all hardware.
Drain radiator according to Section 8-7
and engine manual. Disconnect hoses
at radiator.
Remove rear upright, right fan guard,
and radiator assembly.
Disconnect flexible exhaust pipe at en-
gine manifold.
Disconnect fuel line at engine.
.To aid in reassembly, mark leads
before disconnecting. See lead list
summary in Section 12 for con-
nection information.
Disconnect:
F generator cables from rectifier
assembly
F generator power leads from termi-
nal strip TE1
F engine wiring harness at in-line
connector
F engine ground strap from base.
Use a hoist to evenly lift and remove
engine/generatorassembly.
Go to Section 11-2.
2
Remove brushes
before removing
endbell or rotor.
Ref 804 494-A
2
4
1
3
11-2. Disassembly Of Generator
803 686-B
Y Do not damage stator or rotor win-
dings during this procedure.
Y Use hoist and lifting strap to carefully
remove generator components.
1 Brushes
2 Stator
3 Endbell
4 Rotor
5 Stud
Remove brushes from brushholder assembly
before disassembling generator.
Remove engine and rotor by removing nuts
from studs and separating stator from engine
adapter. With engine properly supported, re-
move hardware securing endbell to stator.
Reassembly Instructions:
Reinstall engine and generator parts as
needed using torque values in table.
Reinstall brushes in brushholder assembly.
Reinstall engine/generator assembly in unit.
Reinstall mounting hardware.
Reconnect fuel line and exhaust pipe
Reinstall radiator and rear upright. Refill ra-
diator with coolant (see Section 8-7 and en-
gine manual).
Reconnect all leads. Use cable ties to secure
leads in existing wiring harness and away
from moving and hot parts.
Reconnect negative () battery cable. Rein-
stall cover, panels, and doors.
A 20 ft lb (27 N
.
m)
B 10 ft lb (14 N
.
m)
C 60 in lb (7 N
.
m)
D 30 ft lb ( 41N
.
m)
Generator
Torques:
4
D
A
5
2
3
B
C
1
11-3. Other Torque Values
Location Hardware Torque
Engine Mounting Bracket to Engine Screw, 31218x .75 Hexwhd.66d Stl Pld Slffmg Taprw 100 ft lb (135 N
.
m)
Upright to Base Screw, 37516x1.00 Hexwhd.66d Stl Pld Slffmg 30 ft lb (41 N
.
m)
Rotor to Flywheel 20 ft lb (27 N
.
m)
Exhaust Pipe to Manifold Screw, M101.5x25 Hex Hdpln 8.8 Pln 30 ft. lb (41 N
.
m)
Engine and Generator Mounting Bolts Screw, 50013 Hex FlangeHd Gr8 Pln 50 ft lb +10/0 (68 N
.
m)
11-4. Replacing Rectifier SCR Modules
Y Stop engine and let cool. Dis-
connect battery negative ()
cable.
.Be sure to follow torque specifica-
tions in table when installing and
connecting SCR module. Retorque
mounting hardware after four
hours.
1 Rectifier Assembly
2 SCR Module 4, 5, 6
3 SCR Module 1, 2, 3
4 SCR Connection Screw
5 SCR Mounting Screw
Remove left side panel. Remove rectifi-
er assembly screws and slowly tilt as-
sembly out.
Remove defective SCR module.
Clean mounting surface where module
will be installed
Apply a thin layer of supplied heat sink
compound to mounting surface of
module.
Install new SCR module. Follow torque
specifications in table when installing
part. Remember to re-torque hard-
ware as specified.
Remove protective foam from SCR ter-
minals (if applicable) before connecting
leads.
SCR Module Torques:
SCR Mounting Screw SCR Connection Screw Terminal
45 in lb, 5 in lb
(5 Nm, 0.5 Nm)
After four hours re-torque to
45 in lb, 5 in lb
(5 Nm, 0.5 Nm)
45 in lb, 5 in lb
(5 Nm, 0.5 Nm)
803 703-B
4
3
1
2
5
SECTION 12 ELECTRICAL DIAGRAMS
.The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model Serial Or Style Number
Circuit
Diagram
Wiring
Diagram
Big Blue 400 CX CC/CV Flux
Core Models
LE341957 Thru LF350568 219 557A
LF350569 And Following 226 564-A See Table 12-1
Big Blue 400 CX CC/CV Models LF350569 And Following 226 566-B See Table 12-2
Circuit Board PC6
(HF Filter Board)
LE341957 And Following 217 005-A
Circuit Board PC2
(Meter Display)
LE341957 And Following 214 535-B
Figure 12-1. Circuit Diagram For Big Blue 400 CX Eff w/ LE341957 Thru LF350568
219 557A
Figure 12-2. Circuit Diagram For Big Blue 400 CX CC/CV Flux Core Eff w/LF350569 And Following
226 564-A
Figure 12-3. Circuit Diagram For Big Blue 400 CX CC/CV Eff w/LF350569 And Following
226 566-B
217 005-A
Figure 12-4. Circuit Board PC6 (HF Filter) Effective w/LE341957 And Following
214 535-B
Figure 12-5. Circuit Board PC2 (Meter Display) Effective w/LE341957 And Following
Table 12-1. Lead List Summary For Big Blue 400CX CC/CV Flux Core Models Eff w/LF350569
.Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-applied
grease had been present.
Lead Connections Lead Connections
PLG1 TO G1
PLG1 TO G2
PLG1 TO K1
PLG1 TO K2
11A STATOR TO RECT.
16A PLG6 (A3) TO R3 RIGHT
16B SCR CV (+) TO R3 (RIGHT)
17A Z1 TO SCRS CC (+)
19A PLG6 (C3) TO R3 LEFT
19A Z1 (CC) TO CC OUTPUT STUD
19B Z1 TO R3 (LEFT)
21A STATOR TO RECT.
30A PLG6 (B3) TO R3 CENTER
30A SCRS () TO NEGATIVE OUTPUT STUD
30B HEAT SINK () TO R3 (CENTER)
31A STATOR TO RECT.
40A CR1 (8) TO PLG5 (1)
40B CR1 (8) TO PLG9 (1)
41A CB1 (BAT) TO STARTER
42A GROUND STUD TO TE1
42A GROUND TERMINAL TO PLG9 (3)
42A S2 (1) TO GROUND TERMINAL
42AA GROUND STUD TO RC11 (PE)
42AB GROUND STUD TO RC12 (PE)
42AC GROUND STUD TO TE2
42B GROUND TERMINAL TO PLG5 (2)
42B S3 (1) TO GROUND TERMINAL
42B TE1 TO BASE GROUND
42C GROUND TERMINAL TO TS1
42C PC6 TO FRT PANEL GROUND
42C PLG6 (J1) TO EXIT
42D FS1 (2) TO GROUND TERMINAL
42E FUEL PUMP TO GROUND TERMINAL
42F SR2 TO GROUND TERMINAL
42G SR3 TO GROUND TERMINAL
42H PC5 (E) TO GROUND TERMINAL
42J CR4 (85) TO GROUND TERMINAL
42K CR3 (85) TO GROUND TERMINAL
42L PC5 (E) TO CT
42M GROUND TERMINAL TO GROUND TERMINAL
42N FUEL LEVEL SENDER TO GROUND TERMINAL
42P FUEL SENDER GROUND TO PLG1 (8)
42Q ENGINE BLOCK GROUND TO GROUND TERMINAL
42R GROUND TERMINAL TO CR2
42TG T15 TO TE1
42Y FRONT PANEL GROUND STUD TO TE1
43A ALT (B) TO CB1 (AUX)
43B CB1 (AUX) TO CB2
43C CB2 TO CB3
43D CR3 (87) TO CB1 (AUX)
44A CR3 (30) TO GLOW PLUG
45A CB3 TO CR1 (6)
47A CR2 TO STARTER
48A CB2 TO S1 (A)
49A SR1 TO R4
50A ALT TO SR1 (+)
51A CR2 TO S1 (C)
51B CR2 TO PLG1 (6)
52A CR4 (87) TO R4
52B R4 TO CR1 (4)
52C CR1 (4) TO SR2
52D SR2 TO CR2
52E CR2 TO PC5 (B)
53A FS1 (1) TO SR2
53B SR2 TO FUEL PUMP
54A CR1 (1) TO PLG1 (7)
55A CR1 (0) TO CR1 (2)
55B CR1 (0) TO S4 (NO)
55C CR1 (2) TO S1 (B)
55D S4 (NO) TO PLG1 (4)
56A S2 (2) TO PLG1 (2)
57A S3 (2) TO PLG1 (3)
58A CR3 (86) TO S4 (WIPER)
60A CR4 (30) TO SR3
60B SR3 TO TS1
61A PC5 (C) TO SR3
61B SR3 TO CR4 (86)
62A PC5 (H) TO S1 (D)
67A PC5 (G) TO CT
70A PLG7 (F2) TO PC5 (J)
71A FUEL SENDER TO PLG1 (5)
80 PC6 EXIT
80A STATOR TO TE1
80B TEI TO PC6 80 LEAD
81A PLG6 (K3) TO CB8
81A STATOR TO CB8
82A STATOR TO TE1
82C TE1 TO CB5
82D CB6 TO CB5
83A STATOR TO TE1
84A STATOR TO TE1
84B STATOR TO T21
85A STATOR TO TE1
87A PC6 CB7
87A RC12 (L) TO CB6
88A STATOR TO TE1
89A STATOR TO TE1
91B PLG10 (1) TO #91 STATOR LEAD
94B RC11 (L) TO CB5
95B CB5 TO RC11
98A STATOR TO TE1
99A CB5 TO RC12
99A STATOR TO TE1
99B STATOR TO T13
99B TE1 TO CB5
100A STATOR TO SPLICE (PC3)
100B PLG10 (5) TO STATOR 100A
101A STATOR TO FUSE 1
103A PLG10 (4) TO T16
104A PLG10 (3) TO T14
105A PLG10 (6) TO BRUSH
106A PLG6 (F3) TO PLG9 (6)
107A PLG6 (D2) TO PLG9 (9)
TM4435 Page 75 Big Blue 400CX
Table 121. Lead List Summary For Big Blue 400CX CC/CV Models Eff w/LF350569 (Continued)
109A PLG6 (E3) TO PLG9 (5)
112A PLG6 (E2) TO PLG9 (11)
113A PLG6 (H3) TO PLG9 (4)
114A PLG10 (8) TO F1
117A PLG6 (G3) TO PLG9 (8)
120A PLG7 (E1) TO PLG9 (2)
121A PLG7 (C3) TO PLG9 (10)
130A PLG6 (J3) TO PLG9 (7)
132A PC6 CB8
135A PLG6 (G2) TO PC6 (6)
136A PLG7 (F1) TO PC6 (8)
137A PLG6 (H2) TO PC6 (9)
140A PLG7 (F3) TO PC6 (10)
141A PLG6 (F2) TO PC6 (4)
148A PLG6 (D3) TO PC6 (2)
150A PLG7 (B3) TO PC6 (7)
160A PLG7 (B1) TO PLG3 (4)
161A PLG7 (A1) TO PLG3 (5)
162A PLG6 (K1) TO PLG3 (6)
165A PLG6 (C2) TO PLG2 (1)
166A PLG6 (B2) TO PLG2 (2)
167A PLG6 (A2) TO PLG2 (3)
180A PLG6 (F1) TO EXIT
181A PLG6 (G1) TO EXIT
182A PLG6 (H1) TO EXIT
188A PLG7 (C1) TO PLG4 (1)
189A PLG7 (D1) TO PLG4 (2)
190A PLG6 (A1) TO PLG5 (3)
191A PLG6 (C1) TO PLG5 (4)
Table 12-2. Lead List Summary For Big Blue 400CX CC/CV Models Eff w/LF350569
.Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-applied
grease had been present.
PLG1 TO G1
PLG1 TO G2
PLG1 TO K1
PLG1 TO K2
11A STATOR TO RECT.
16A PLG6 (A3) TO R3 RIGHT
16B SCR CV (+) TO R3 (RIGHT)
17A Z1 TO SCRS CC (+)
19A PLG6 (C3) TO R3 LEFT
19A Z1 (CC) TO CC OUTPUT STUD
19B Z1 TO R3 (LEFT)
21A STATOR TO RECT.
30A PLG6 (B3) TO R3 CENTER
30A SCRS () TO NEGATIVE OUTPUT STUD
30B HEAT SINK () TO R3 (CENTER)
31A STATOR TO RECT.
40A CR1 (8) TO PLG5 (1)
40B CR1 (8) TO PLG9 (1)
41A CB1 (BAT) TO STARTER
42A GROUND STUD TO TE1
42A GROUND TERMINAL TO PLG9 (3)
42A S2 (1) TO GROUND TERMINAL
42AA GROUND STUD TO RC11 (PE)
42AB GROUND STUD TO RC12 (PE)
42AC GROUND STUD TO TE2
42AD GFCI1 (GRND) TO GROUND STUD
42B GROUND TERMINAL TO PLG5 (2)
42B S3 (1) TO GROUND TERMINAL
42B TE1 TO BASE GROUND
42C GROUND TERMINAL TO TS1
42C PC6 TO FRT PANEL GROUND
42C PLG6J1 TO EXIT
42D FS1 (2) TO GROUND TERMINAL
42E FUEL PUMP TO GROUND TERMINAL
42F SR2 TO GROUND TERMINAL
42G SR3 TO GROUND TERMINAL
42H PC5 (E) TO GROUND TERMINAL
42J CR4 (85) TO GROUND TERMINAL
42K CR3 (85) TO GROUND TERMINAL
42L PC5 (E) TO CT
42M GROUND TERMINAL TO GROUND TERMINAL
42N FUEL LEVEL SENDER TO GROUND TERMINAL
42P FUEL SENDER GROUND TO PLG1 (8)
42Q ENGINE BLOCK GROUND TO GROUND TERMINAL
42R GROUND TERMINAL TO CR2
42S PERSONALITY CONNECTION
42T PERSONALITY CONNECTION
42TG T15 TO TE1
42W PERSONALITY CONNECTION
42X PERSONALITY CONNECTION
42Y FRONT PANEL GROUND STUD TO TE1
43A ALT (B) TO CB1 (AUX)
43B CB1 (AUX) TO CB2
43C CB2 TO CB3
43D CR3 (87) TO CB1 (AUX)
44A CR3 (30) TO GLOW PLUG
45A CB3 TO CR1 (6)
47A CR2 TO STARTER
48A CB2 TO S1 (A)
49A SR1 TO R4
50A ALT (D+) TO SR1 (+)
51A CR2 TO S1 (C)
51B CR2 TO PLG1 (6)
52A CR4 (87) TO R4
52B R4 TO CR1 (4)
52C CR1 (4) TO SR2
52D SR2 TO CR2
52E CR2 TO PC5 (B)
53A FS1 (1) TO SR2
53B SR2 TO FUEL PUMP
54A CR1 (1) TO PLG1 (7)
55A CR1 (0) TO CR1 (2)
55B CR1 (0) TO S4 (NO)
55C CR1 (2) TO S1 (B)
55D S4 (NO) TO PLG1 (4)
56A S2 (2) TO PLG1 (2)
57A S3 (2) TO PLG1 (3)
58A CR3 (86) TO S4 (WIPER)
60A CR4 (30) TO SR3
60B SR3 TO TS1
61A PC5 (C) TO SR3
61B SR3 TO CR4 (86)
62A PC5 (H) TO S1 (D)
67A PC5 (G) TO CT
70A PLG7 (F2) TO PC5 (J)
71A FUEL SENDER TO PLG1 (5)
80 PC6 EXIT
80A STATOR TO TE1
81A PLG6 (K3) TO CB8
81A STATOR TO CB8
82A STATOR TO TE1
82C TE1 TO ELCB1LINE
82D TE1 TO ELCB2 LINE
83A STATOR TO TE1
84A STATOR TO TE1
84B STATOR TO T21
84B TE1 TO CB5
85A STATOR TO TE1
87A PC6 CB7
87A RC11 (L) TO ELCB2LOAD
88A STATOR TO TE1
89A STATOR TO TE1
90D CB5 TO GFCI1 (H)
94B RC12 (L) TO ELCB1LOAD
95B ELCB1LOAD (N) TO RC12
96A ELCB2LOAD (N) TO RC11
98A STATOR TO TE1
99A STATOR TO TE1
99B STATOR TO T13
99B TE1 TO ELCB1 LINE (N)
99C TE1 TO ELCB2 LINE (N)
99D TE1 TO GFCI1 (N)
100A STATOR TO SPLICE (PC3)
100B PLG10 (5) TO STATOR 100A
101A STATOR TO FUSE 1
103A PLG10 (4) TO T16
104A PLG10 (3) TO T14
106A PLG6 (F3) TO PLG9 (6)
107A PLG6 (D2) TO PLG9 (9)
109A PLG6 (E3) TO PLG9 (5)
112A PLG6 (E2) TO PLG9 (11)
113A PLG6 (H3) TO PLG9 (4)
114A PLG10 (8) TO F1
117A PLG6 (G3) TO PLG9 (8)
120A PLG7 (E1) TO PLG9 (2)
121A PLG7 (C3) TO PLG9 (10)
130A PLG6 (J3) TO PLG9 (7)
132A PC6 CB8
135A PLG6 (G2) TO PC6 (6)
136A PLG7 (F1) TO PC6 (8)
137A PLG6 (H2) TO PC6 (9)
140A PLG7 (F3) TO PC6 (10)
141A PLG6 (F2) TO PC6 (4)
148A PLG6 (D3) TO PC6 (2)
150A PLG7 (B3) TO PC6 (7)
160A PLG7 (B1) TO PLG3 (4)
161A PLG7 (A1) TO PLG3 (5)
162A PLG6 (K1) TO PLG3 (6)
TM4435 Page 77 Big Blue 400CX
Table 122. Lead List Summary For Big Blue 400CX CC/CV Models Eff w/LF350569 (Continued)
165A PLG6 (C2) TO PLG2 (1)
166A PLG6 (B2) TO PLG2 (2)
167A PLG6 (A2) TO PLG2 (3)
180A PLG6 (F1) TO EXIT
181A PLG6 (G1) TO EXIT
182A PLG6 (H1) TO EXIT
188A PLG7 (C1) TO PLG4 (1)
189A PLG7 (D1) TO PLG4 (2)
190A PLG6 (A1) TO PLG5 (3)
191A PLG6 (C1) TO PLG5 (4)
SECTION 13 RUN-IN PROCEDURE
run_in1 11/05
13-1. Wetstacking
Y Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
1 Welding Generator
Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
. 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.
2
1
13-2. Run-In Procedure Using Load Bank
S-0683
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
from flammables.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe correct
polarity.
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator A/V control so
load equals rated voltage and
current of generator (see name-
plate, rating label, or the specifi-
cations section in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
.Check oil level frequently dur-
ing run-in; add oil if needed.
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.
Repeat procedure if wetstacking is
present.
2
3
1
4
13-3. Run-In Procedure Using Resistance Grid
S-0684
Y Stop engine.
Y Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y Keep exhaust and pipe away
from flammables.
1 Resistance Grid
Use grid sized for generator rated
output.
Turn Off grid.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connec-
tors (polarity is not important).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several
minutes.
Set grid switches and then ad-
just generator A/V control so
load equals rated voltage and
current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
.Check oil level frequently dur-
ing run-in; add oil if needed.
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.
Repeat procedure if wetstacking is
present.
1
3 5
+
4
2
6
Visit our website at
www.MillerWelds.com
Eff w/LE341957 And Following
For OM-4435 (218 759) Revision A Thru F
Big Blue 400 CX
Processes
TM-4435B 200605
Eff. w/Serial Number LE341957
Description
Engine Driven Welding Generator
Air Carbon Arc (CAC-A) Cut-
ting and Gouging
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
)
SECTION 14 PARTS LIST EFFECTIVE WITH LE341957
.Hardware is common and not
available unless listed.
Wiring harnesses are listed at
the end of parts section.
2Fig.14-4
3
7
4Fig.14-6 or 14-7
104
8
9
5
10
11
12
14
15
13
16
17 103
101
100
18
19
20
21
22
23
91
92
84
83
82
81
80
85
86
90
89
88
87
94
95
96
97Fig.14-2 or 14-3
106
1
24
25
93
99
102
6
98
105
Figure 14-1. Main Assembly (CC/CV Model Shown)
804 012B
55
73
75
74
76
77
78
79
72Fig.14-5
70
69
68
67
66
64
56
58
57
59
60
63
62
61
36
37
38
39
40
41
44
45
49
50
51
52
46
53
54
55
48
47
46
33
34
35
32
31
30
29
28
27
26
65
71
42
43
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 14-1. Main Assembly
Quantity
1 HD1 168829 Transducer, Current 1000a Module Max Open Loop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Figure 14-5 Control Panel 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 217070 Bracket, Rectifier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Figure 14-7, Figure 14-8 Rectifier Assembly 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
181853 Insulator, Screw (For Rectifier Mtg) 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Z1 213929 Stabilizer 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
192303 Angle, Mtg Stabilizer 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 215522 Bracket, Vault 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 +213488 Panel, Engine Side 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 PC1 220739 Module, Main Control/Scr Gating 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 PC3 214770 Module, Voltage Regulator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 213493 Upright, Center Assy 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 189464 Seal, Weather Lift Eye 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 213501 Bracket, Fuel Pump/Filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Bracket, Fuel Filter Mtg. (Order Thru Engine Manufacturer) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 217687 Filter, Fuel Spinon 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 207721 Pump, Fuel 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 *213858 Filter, Fuel Inline 5/16x5/16 Mic 125 175 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 214753 Bracket, Holddown Fuel Tank 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 213602 Gasket, Exhaust Outlet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 212621 Pipe, Exhaust Flexible Inlet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 183314 Clamp, Muffler 1.625 Dia U Pld 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 212604 Baffle, Air Lower Radiator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 201528 Muffler, Exhaust Engine (Prior to LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 226018 Muffler, Exhaust Engine (Eff w/LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 213580 Pipe, Exhaust Spark Arrestor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 088528 Spark Arretsor, Exhaust 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 201399 Pipe, Exhaust Extension 5.0 Long 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 +213470 Cover, Top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
049525 Nut, 31218 Unut Multithread 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 189052 Grommet, Plastic Neck Filler Fuel 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 190198 Cap, Tank Screwon 3.500 In W/Vent W/Lanyard 8 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 176104 Label, Warning Falling Equipment Can Cause Serious (Prior to LF310974)1 . . . . . . . . . . . . . . . . . . .
29 222513 Label, Warning Falling Equipment Can Cause Serious (Eff w/LF310974) 1 . . . . . . . . . . . . . . . . . . .
30 201851 Cover, Radiator Access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 214604 Pipe, Exhaust Elbow 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 176230 Label, Hot Exhaust Parts Do Not Touch (Prior to LF310974) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 224265 Label, Warning Hot Exhaust Parts Do Not Touch (Eff w/LF310974) 2 . . . . . . . . . . . . . . . . . . . . . . . .
32 224265 Label, Warning Hot Exhaust Parts Do Not Touch (Eff w/LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . .
33 176103 Label, Use Diesel Fuel Only (Prior to LF310974) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 192041 Label, Use Diesel Fuel Only (Eff w/LF310974) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 213472 Keeper, Latch Engine Access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 213471 Bracket, Cover Top 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 217387 Baffle, Fan 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 213503 Guard, Fan 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 +212607 Shroud, Radiator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 212606 Radiator, W/14# Cap 3 Row Core 1.25 In Inlet/Outlet (Prior to LF350569) 1 . . . . . . . . . . . . . . . . . . .
39 226121 Radiator, W/14# Cap 3 Row Core 1.25 In Inlet/Outlet (Eff w/LF350569) 1 . . . . . . . . . . . . . . . . . . . .
40 212603 Baffle, Air Upper Radiator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 +220954 Upright, Rear (Prior to LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 +225400 Upright, Rear (Eff w/LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 225412 Cover, Radiator Access (Eff w/LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 220295 Bracket, Stiffener 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 190190 Tank, Coolant Recovery 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 213502 Guard, Fan 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 176106 Label, Warning Moving Parts Can Cause Serious (Prior to LF310974) 4 . . . . . . . . . . . . . . . . . . . . .
46 225120 Label, Warning Moving Parts Can Cause Injury (Eff w/LF310974) 4 . . . . . . . . . . . . . . . . . . . . . . . . .
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 14-1. Main Assembly (Continued)
Quantity
47 217698 Label, Help Codes 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 176108 Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . .
(Prior to LF310974 and Eff w/LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 168385 Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . .
(Eff w/LF310974 thru LF350568) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 176109 Label, Caution Using Ether To Aid Engine Etc (Prior to LF310974) 1 . . . . . . . . . . . . . . . . . . . . . . . .
49 203260 Label, Caution Do Not Use Ether (Eff w/LF310974) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 215268 Label, Diesel Engine Maintenance Cat 3013c 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51 199592 Latch, Paddle Series 20 (Black) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52 +213487 Door, Engine Access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
191626 Bumper, Door Engine Access 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53 189975 Hinge, Door Access 180 Deg 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54 087341 Bumper, Door 1.000 Od X .750 High Rbr 50 Duro W/O 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55 213486 Panel, Rocker 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56 213266 Mount, Engine/Generator Flange Mtg 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57 197506 Screw, M141.5x 30 Hex Hdpln 8.8 Pln 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58 213480 Bracket, Mtg Engine 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59 083883 Washer, Lock .402idx0.709odx.087t Stl Split10mm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60 049026 Screw, M101.5x 25 Hex Hdpln 8.8 Pln 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
199505 Hose Assy, Oil Drain 32.000 Lg (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61 113854 Hose, Sae .500 Id X .780 Od Xcoil 2.6 Ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62 176529 Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63 165271 Valve, Oil Drain 3/818 Nptf 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
197448 Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 3/8 Npt 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
212612 Ftg, Adapter Oil Drain Cat 3013 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64 212614 Hose, Radiator Lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65 217686 Belt, Alternator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66 210792 Engine, Cat Dsl Elec 3013c (1800) Series 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*202166 Filter, Oil Cat1504140 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
217695 Switch, Coolant Temp N.C. 110c 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67 212613 Hose, Radiator Upper 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68 216811 Clip, Nut Retaining 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69 197613 Air Cleaner, Intake 5.250 In (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
197675 Dust Ejector, Air Cleaner 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*197676 Element, Air Cleaner 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
197677 Cover Assy, Air Cleaner 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
197678 Body, Air Cleaner 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*197679 Element, Air Cleaner Safety 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
197829 Bracket, Mtg Air Cleaner 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70 212617 Hose, Air Intake 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71 217696 Switch, Lubricating Oil Pressure N.O. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72 Figure 14-6 Generator Assembly 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73 213461 Bracket, Mtg Generator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
212623 Tank, Fuel (Includes Fuel Cap And Items Below) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74 189908 Valve, Drain Fuel 180 Deg Zinc Pld 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75 181572 Bushing, Tank Fuel 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76 124253 Bushing, Tank Fuel 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77 212611 Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78 212610 Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79 SENDER 213265 Sender, Fuel Gauge 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
172071 Clamp, Hose .520 .605 Clp Dia Slfttng Black 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134835 Hose, Sae .312 Id X .560 Od (order by foot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
145054 Hose, Sae .187 Id X .410 Od X 26.000 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80 213465 Bolt, J Stl .31218 X 7.250 Pld 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81 213466 Bracket, Battery Holddown 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82 BATT 111352 Battery, Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83 190207 Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 14-1. Main Assembly (Continued)
Quantity
190206 Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84 213668 Bracket, Mtg Unit 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85 200864 Label, Warning Do Not Weld On Base (Prior to LF310974) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85 224266 Label, Warning Do Not Weld On Base (Eff w/LF310974) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86 213458 Base 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87 213460 Crossmember, Generator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88 213463 Spacer/Snubber, Generator Mtg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89 213462 Pad, Mtg Generator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90 213459 Crossmember, Engine 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
213670 Screw, 50013x2.25 Hex Flangehd Gr8 Pln Chem/Phys 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
071731 Washer, Flat .656idx2.250odx.187t Stl Pld 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
213600 Screw, 50013x3.00 Hex Flangehd Gr8 Pln 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
071731 Washer, Flat .656idx2.250odx.187t Stl Pld 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
213464 Bracket, Battery Locator (In Base Not Shown) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91 213485 Support, Engine Lh 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92 213483 Support, Engine Rh 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93 200865 Label, Ce Sound Power Level 98db (Prior to LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93 226150 Label, Ce Sound Power Level 96db (Eff w/LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
94 +220953 Upright, Front (Prior to LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
94 +226104 Upright, Front (Eff w/LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95 176105 Label, Warning General Precautionary (Prior to LF310974) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95 223379 Label, Warning General Precautionary (Eff w/LF310974 thru LF350568) 1 . . . . . . . . . . . . . . . . . . .
95 223378 Label, Warning General Precautionary (Eff w/LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96 220955 Panel, Front Access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97 Figure 14-3, Figure 14-4 Front Panel Assembly 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
98 CT1 105370 Xfmr, Current 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99 218449 Label, Rating Card Code 154 (Prior to LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
173216 Label, CE European Community Mark (Prior to LF350659) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99 226163 Label, Rating Card Ce 907143 (CC Model) (Eff w/LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99 226422 Label, Rating Card Ce 907281 (CC/CV Model) (Eff w/LF350569) 1 . . . . . . . . . . . . . . . . . . . . . . . . .
100 213504 Tray, Reactor&Rectifier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101 213500 Brkt, Beam Support 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102 T1 220887 Xfmr, Isolation 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103 TE1 172661 Block, Stud Connection 6 Position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104 C11 217054 Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105 214742 Capacitor Assy, (CC/CV Model) (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
213489 Bus Bar,Capacitor Bank Negative 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
213490 Bus Bar,Capacitor Bank Positive 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C10 163535 Capacitor,Elctlt 16000 Uf 60 Vdc Can 1.75 Dia 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106 R3 213027 Resistor, WW Tap 300 W 40 Ohm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
173734 Link, Jumper 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
213506 Bracket, HoldDown Fuel Tank (Not Shown) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
218460 Kit, Label (Includes Safety And Informational Labels) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
214887 Idle, Solenoid Assy (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
213505 Bracket, Mtg Solenoid Idle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TS1 080517 Solenoid,12vdc Pull Type Tubular 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
049839 Bracket, Adjustment Solenoid 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
605277 Pin,Cotter .093 X .750 Zinc Pld 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
198370 Rod,Throttle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
206209 Ball Joint,.25028 Thd 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
198609 Arm,Throttle 104.22 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
085963 Spring, Ext .375 Od X .041 Wire X 2.000 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Recommended Spare Parts. Optional
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Wirng harnesses are listed at
804 011A
1
2
3
4
5
6
36
35
7
8
9
10
11
12
13
14
15
16
17
18
19
30
31
32
33
34
28
29
24
20
21
22
25
26
27
23
Figure 14-2. Panel, Front w/Components Prior To LF350569
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 14-2. Panel, Front w/Components Prior To LF350569 (Figure 14-1 Item 97 )
Quantity
1 097926 Knob, Pointer 2.375 Dia X .250 Id W/Set Screwsplstc 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 072590 Lock, Shaft Pot .37532 X .250 Dia Shaft Tall 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 170391 Conn, Circ Ms Protective Cap Size 20 Nylon 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 206795 Boot, Circuit Breaker Clear Hex Nut 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 097922 Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Nameplate, Control (Order By Model & Serial No.) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 PC6 217008 Circuit Card Assy, Connector/Receptacle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 CB8 083432 Circuit Breaker, Man Reset 1p 10a 250vac Frict 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 214864 Panel, Front Engine/Weld Control 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 214762 Bracket, Meter Hole Cover 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 214543 Enclosure, Circuit Card Assy 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 134201 Standoff Support, Pc Card .312/.375w/Post&lock .43 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 PC2 214660 Circuit Card Assy, Display W/Program 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 R1 214760 Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 R2 193118 Pot, Cp Flat 1t 2. W 1k Ohm Linear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 S4 021467 Switch, Tgl Spst 3a 250v Offnone(On) Spd Term 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 14-2. Panel, Front w/Components Prior To LF350569 (Continued)
Quantity
16 S1 212436 Switch, Ignition 4 Position (Includes Knob) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 039047 Terminal, Pwr Output Red 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 010381 Connector, Rectifier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 C13, 14 128750 Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 RC12 176355 Rcpt, Str 2p3w 16a 220v Flange Mtg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 CB6 201083 Circuit Breaker,Man Reset 2p 20a 250vac 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 Nameplate, Generator Power (Order By Model & Serial No.) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 213478 Panel, Power 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 CB5 202683 Supplementary Protector, Man Reset 2p 40a 240vac (Prior to LE409822) 1 . . . . . . . . . . . . .
24 CB5 222187 Supplementary Protector, Man Reset 2p 35a 240vac (Eff w/LE409822) 1 . . . . . . . . . . . . .
25 GRD 083030 Stud, Brs .25020 X 1.750 W/Hex Collar 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 010915 Washer, Flat .257idx0.640odx.031t Brs 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 601836 Nut, 25020 .50hex .19h Brs 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 RC11 156831 Rcpt,Str 2p3w 32a 220v Flange Mtg 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 209056 Cover, Receptacle W/Gasket 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 Nameplate, Weld Terminal (Order By Model & Serial No.) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 181169 Spacer, Output Stud 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 186621 Boot, Generic Output Stud 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 180735 Washer, Output Stud 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 039046 Terminal, Pwr Output Black 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 FUEL/HM 214768 Gauge, Fuel Elec/Hour Meter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 021385 Boot, Toggle Switch Lever 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 218 460
804 011B
1
2
3
4
5
6
41
40
7
8
9
10
11
12
13
14
15
16
17
18
19
35 36
37
38
39
33
28
20
22
30
31
32
23
27
25
26
24
21
34
29
Figure 14-3. Panel, Front w/Components (CC Model) Effective W/LF350569
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 14-3. Panel, Front w/Components (CC Model) Effective W/LF350569 (Figure 14-1 Item 97 )
Quantity
8 CB8 083432 Supplementary Pro, Man Reset 1p 10a 250vac Frict 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 14-3. Panel, Front w/Components (CC Model) Effective W/LF350569 (Continued)
Quantity
21 206795 Boot, Circuit Breaker Clear Hex Nut 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 224428 Panel, Power CE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 GFCI1 151981 Rcpt, Str Dx Grd 2p3w 15/20a 125v *520r Gfi 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 C11, 12 217054 Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 ELCB1 222991 Circuit Breaker, Elcb 20a 220v 0.030a Trip 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 144844 Standoff, No 632 X .875 Lg .250 Hex Al Fem 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 601836 Nut, 25020 .50hex .19h Brs 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional
804 443-A
1
2
3
4
5
6
37
36
7
8
9
10
11
12
13
14
15
16
17
18
19
31
32
33
34
35
30
25
20
22
27
28
29
23
24
26
21
Figure 14-4. Panel, Front w/Components (CC/CV Model) Effective W/LF350569
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 14-4. Panel, Front w/Components (CC/CV Model) Effective W/LF350569 (Figure 14-1 Item 97)
Quantity
Description
Part
No.
Dia.
Mkgs.
Item
No. Quantity
Figure 14-4. Panel, Front w/Components (CC/CV Model) Effective W/LF350569 (Continued)
23 224428 Panel, Power CE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 144844 Standoff, No 632 X .875 Lg .250 Hex Al Fem 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 601836 Nut, 25020 .50hex .19h Brs 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional
803 689-C
1
2
3
4
5
6
7
8
9
10
13
12
11
14
Figure 14-5. Control Panel
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 14-5. Control Panel (Figure 14-1 Item 2)
Quantity
1 220981 Bracket, Mtg Components 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 129524 Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 CR2 214876 Relay, Encl 6vdc Spst 35a/14vdc 5 Pin 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 CB1 190374 Circuit Breaker, Auto Reset 12vdc 40 Amp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 CR1 199999 Relay, Encl 12vdc Dpstno 30a 6pin Flange (Prior to LF065150) 1 . . . . . . . . . . . . . . . . . . . .
5 CR1 223669 Relay Assy, (Eff w/LF065150 Thru LF310974) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 CR1 223710 Relay, Encl 12vdc Dpstno 25a 6pin Flange (Eff w/LF310974) 1 . . . . . . . . . . . . . . . . . . . . . .
6 046432 Holder, Fuse Mintr .250 X 1.250 Panel Mtg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 F1 085874 Fuse, Mintr Cer Sloblo 10. Amp 250 Volt 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 R4 217335 Resistor Board 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 CR4 090104 Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 CR3 197325 Relay, Encl 12vdc Spst 70a 4pin Flange Mtg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 SR3 035704 Rectifier, Integ Bridge 40. Amp 800v 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 SR1, SR2 035704 Rectifier, Integ Bridge 40. Amp 800v 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 PC5 214761 Module, Pull To Idle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 CB2, CB3 083432 Supplementary Pro, Man Reset 1p 10a 250vac Frict 2 . . . . . . . . . . . . . . . . . . . . . . . . .
Optional
803 686-A
2
3
1
4
5
6
7
8
9
10
11
12
13
14
19
20 18
15
17
16
Figure 14-6. Generator
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 14-6. Generator (Figure 14-1 Item 71)
Quantity
1 ROTOR 212474 Rotor, Generator 4 Pole (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 053390 Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 192600 Fan, Generator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 159918 Baffle, Fan 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 212126 Adapter, Engine Machined Cat 3013c 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 602211 Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 192686 Screw, M 81.25x 25 Hex Hdpln 8.8 Pld Din933 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 602211 Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 192686 Screw, M 81.25x 25 Hex Hdpln 8.8 Pld Din933 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 212641 Stud, Stl .37516 1.625x 19.000 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 STATOR 219920 Stator, Generator 4 Pole 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 160943 Endbell 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 167788 Nut, 37516 .56hex .34h Stl Pld Sem Cone Wshr.88d 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 218552 Brush, Assembly 2 Pole (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 047879 Bar, Retaining Brushholder 2 Brushes 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 161306 Cap, Brushholder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 126984 Brush w/Spring 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 005614 Holder, Brush 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 125548 Holder, Brush Elect 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 158832 Screw, 01032x .50 Hex Hdslt Stl Pld Sq Cone Sems 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
804 010A
the end of parts section. 1
3
2
5
4
6
Figure 14-7. Rectifier Assembly For CC Models
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 14-7. Rectifier Assembly (Figure 14-1 Item 4)
Quantity
217082 Rectifier, Assembly (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 211984 Heat Sink 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 212601 Insulator, Rectifier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 MOD1,2,3 196760 Thyristor, Scr Module 190a 400v Dual 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 217085 Bus Bar, Rectifier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 C16 215611 Capacitor Assy 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 TH1 213930 Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
181853 Insulator, Screw (For Mounting Rectifier) 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
803 685-A
1
2
3
6
4
5
9
8
10
7
Figure 14-8. Rectifier Assembly For CC/CV Models
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 14-7. Rectifier Assembly (Figure 14-1 Item 4)
Quantity
217081 Rectifier, Assembly (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 211984 Heat Sink 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 MOD1,2,3 218296 Kit, Module SCR 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 MOD4,5,6 218292 Kit, Module SCR 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 212601 Insulator, Rectifier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 TH1 213930 Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 C16 215611 Capacitor Assy 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 C7,8,9 048420 Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
181853 Insulator, Screw (For Mounting Rectifier) 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Some wiring harness components (switches, relays, circuit breakers) are also referenced
elsewhere in this parts list. Purchase components separately or as part of the associated
wiring harness.
Note
Description
Part
No.
Dia.
Mkgs.
Item
No.
Wiring Harnesses
Quantity
219231 Harness, Engine CAT (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S4 021467 Switch, Tgl Spst 3a 250v Offnone(On) Spd Term 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SR1, SR2 035704 Rectifier, Integ Bridge 40. Amp 800v 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CB1 190374 Circuit Breaker, Auto Reset 12vdc 40 Amp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CB2, CB3 083432 Supplementary Pro, Man Reset 1p 10a 250vac Frict 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CR3 197325 Relay, Encl 12vdc Spst 70a 4pin Flange Mtg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CR2 214876 Relay, Encl 6vdc Spst 35a/14vdc 5 Pin 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
217335 Resistor Board 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
148850 Socket, Relay 5 Pin 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
212116 Conn, Deutsch 2p 1row Female Plug 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
212117 Conn, Deutsch Wedge Lock 2 Position 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG1 214932 Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
214933 Seal, Wire Univ 039 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
214934 Seal, Plug Univ 039 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For S1 211292 Conn, Pack 4p 1row Female 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For S1 211293 Conn, Pack Terminal Position Assurance (Lock) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129524 Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
221864 Harness, Weld Control CE (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG2 150316 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG9 214951 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
214933 Seal, Wire Univ 039 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
214934 Seal, Plug Univ 039 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG8 147992 Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG6 193184 Conn, Rect Cinch 30 Pin 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG7 193183 Conn, Rect Cinch 18 Pin 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG9 215261 Conn, Deutsch 12p 2row Female Plug 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG10 215262 Conn, Deutsch 12p 2row Female Plug 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
215265 Conn, Deutsch Wedge Lock 12 Position 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
215343 Seal, Plug Deutsch 1216 Size 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG5 113750 Conn, Rect Mini 045 4skt 2row Plug Cable Lkg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
217000 Cable, Lem 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
215340 Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
214933 Seal, Wire Univ 039 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
214982 / 214984 Harness, Rectifier (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG11 193183 Conn, Rect Cinch 18 Pin 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
207716 Conn, Faston Mini Polarized 2 Skt G1k1 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
207718 Conn, Faston Mini Polarized 2 Skt G2k2 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
217010 Harness, Receptacle Auxiliary Power 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRINTED IN USA 2006 Miller Electric Mfg. Co.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International HeadquartersUSA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066

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