BIG BLUE 300 P (LE099775)

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TM-4433D 2009 07Eff. w/LE099775 Thru LJ120230E

Processes

Description

Air Carbon Arc (CAC-A) Cuttingand Gouging

Stick (SMAW) Welding

Engine Driven Welding Generator

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Visit our website at

www.MillerWelds.com

Big Blue 300 P

File: Engine Drive

8/10/2019 BIG BLUE 300 P (LE099775)

2/92TM-4433Big Blue 300 P

INFORMATION ON OLDER UNITS

This manual includes operating information for current units. To obtain specific operating information for older models, download the applicableOwners Manual from www.MillerWelds.com .

Eff w/LG440030E, engine speed adjustment procedures changed. For older models, download applicable Owners Manual from www.Miller-Welds.com.

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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 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4. EMF Information 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 DEFINITIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Warning Label Definitions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Manufacturers Rating Label 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Symbols And Definitions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 SPECIFICATIONS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Weld, Power, And Engine Specifications 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2. Dimensions, Weights, And Operating Angles 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3. Volt-Ampere Curves 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4. Fuel Consumption 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5. Duty Cycle And Overheating 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6. AC Generator Power Curve 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Installing Welding Generator 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Mounting Welding Generator 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. Installing Exhaust Pipe 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4. Activating The Dry Charge Battery (If Applicable) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Connecting The Battery 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6. Engine Prestart Checks 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7. Connecting To Weld Output Terminals 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8. Selecting Weld Cable Sizes* 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9. Connecting To Remote 14 Receptacle RC14 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 OPERATING WELDING GENERATOR 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Front Panel Controls (See Section 5-2) 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Description Of Front Panel Controls (See Section 5-1) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Process/Contactor Switch 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. Lift-ArcE Start Procedure 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. Remote Voltage/Amperage Control 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 OPERATING AUXILIARY EQUIPMENT 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Generator Power Receptacles 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 MAINTENANCE 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. Routine Maintenance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. Maintenance Label 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3. Servicing Air Cleaner 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4. Inspecting And Cleaning Optional Spark Arrestor Muffler 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5. Servicing Engine Cooling System 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6. Adjusting Engine Speed On Standard Models 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7. Adjusting Engine Speed On Models With Automatic Idle (Optional) 31. . . . . . . . . . . . . . . . . . . . . . . . . . .7-8. Servicing Fuel And Lubrication Systems 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9. Overload Protection 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10. Checking Generator Brushes 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11. Voltmeter/Ammeter Help Displays 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 THEORY OF OPERATION 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 9 TROUBLESHOOTING 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Troubleshooting Tables 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 9-3) 44. . . . . . . . . . . . . . . .9-3. Troubleshooting Values For Circuit Diagram (Use With Section 9-2) 46. . . . . . . . . . . . . . . . . . . . . . . . . .9-4. Waveforms For Sections 9-2 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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9-5. Filter Board PC6 Testing Information 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6. Filter Board PC6 Test Point Values 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7. Module Testing Information 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8. Main Control Board PC1 Testing Information 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9. Main Control Board PC1 Test Point Values 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10. Voltage Regulator Board PC3 Testing Information 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11. Voltage Regulator Board PC3 Test Point Values 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12. Meter Display Board PC2 Testing Information 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13. Meter Display Board PC2 Test Point Values 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14. Idle Module PC5 Testing Information And Troubleshooting Flow Chart 58. . . . . . . . . . . . . . . . . . . . . . . .9-15. Replacing Brushes And Cleaning Slip Rings 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16. Checking Unit Output After Servicing 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 DISASSEMBLY AND REASSEMBLY 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1. Disassembly Of Unit 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2. Disassembly Of Generator 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3. Replacing Rectifier SCR Modules 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 ELECTRICAL DIAGRAMS 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 12 RUN-IN PROCEDURE 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1. Wetstacking 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2. Run-In Procedure Using Load Bank 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-3. Run-In Procedure Using Resistance Grid 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 PARTS EFF W/LE099775 THRU LJ120250E 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TM-4433 Page 1Big Blue 300 P

SECTION 1 SAFETY PRECAUTIONS FOR SERVICINGProtect yourself and others from injury read and follow these precautions.

1-1. Symbol UsageOM-4433P - 2007 11, safety_rtm 2009 07

DANGER! Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.

Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards are shown in the adjoining symbols or ex-plained in the text.

NOTICE Indicates statements not related to personal injury.

Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-bols and related instructions below for necessary actions to avoid thehazards.

1-2. Servicing Hazards

The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard.

Only qualified persons should test, maintain, and repair thisunit.

During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Do not touch live electrical parts.Stop engine and remove input power plug fromreceptacle (if applicable) before testing or re-pairing unit unless the procedure specificallyrequires an energized unit.

Insulate yourself from ground by standing or working on dry insu-lating mats big enough to prevent contact with the ground.Do not leave live unit unattended.If this procedure requires an energized unit, have only personnelfamiliar with and following standard safety practices do the job.When testing live unit, use the one-hand method. Do not put bothhands inside unit. Keep one hand free.

SIGNIFICANT DC VOLTAGE exists in inverter powersources AFTER stopping engine.

Stop engine on inverter and discharge input capacitors accordingto instructions in Troubleshooting Section before touching anyparts.

MOVING PARTS can injure.

Keep away from moving parts such as fans,belts, and rotors.Keep away from pinch points such as driverolls.Have only qualified people remove doors,panels, covers, or guards for maintenanceand troubleshooting as necessary.Keep hands, hair, loose clothing, and toolsaway from moving parts.

Before working on generator, remove spark plugs or injectorsto keep engine from kicking back or starting.Block flywheel so that it will not turn while working on genera-tor components.Reinstall doors, panels, covers, or guards when servicing isfinished and before starting engine.

FLYING METAL or DIRT can injure eyes.

Wear safety glasses with side shields or faceshield during servicing.Be careful not to short metal tools, parts, orwires together during testing and servicing.

STATIC (ESD) can damage PC boards.Put on grounded wrist strap BEFORE handlingboards or parts.Use proper static-proof bags and boxes tostore, move, or ship PC boards.

Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide.This is a poison you cannot see or smell.NEVER use inside a home or garage, EVEN IFdoors and windows are open.

Only use OUTSIDE and far away from windows, doors, andvents.

FUEL can cause fire or explosion.

Stop engine and let it cool off before checking oradding fuel.Do not add fuel while smoking or if unit is nearany sparks or open flames.

Do not overfill tank; clean up any spilled fuel.

FIRE OR EXPLOSION hazard.Do not place unit on, over, or near combustible surfaces.

Do not service unit near flammables.

BATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, andprotective clothing when working on a battery.Stop engine before disconnecting or connect-ing battery cables.

Do not allow tools to cause sparks when working on a battery.Do not use welder to charge batteries or jump start vehicles.Observe correct polarity (+ and ) on batteries.Disconnect negative ( ) cable first and connect it last.

BATTERY ACID can BURN SKIN and EYES.

Do not tip battery.Replace damaged battery.Flush eyes and skin immediately with water.

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TM-4433 Page 2 Big Blue 300 P

STEAM AND HOT COOLANT can burn.

If possible, check coolant level when engine iscold to avoid scalding.

Always check coolant level at overflow tank, if present on unit, instead of radiator.

If the engine is warm, checking is needed, and there is no over-flow tank, follow the next two statements.Wear safety glasses and gloves and put a rag over radiator cap.Turn cap slightly and let pressure escape slowly beforecompletely removing cap.

MAGNETIC FIELDS can affect ImplantedMedical Devices.

Wearers of Pacemakers and other ImplantedMedical Devices should keep away from serv-icing areas until consulting their doctor and thedevice manufacturer.

FALLING EQUIPMENT can injure.Use lifting eye to lift unit and properly installedaccessories only, NOT gas cylinders. Do notexceed maximum lift eye weight rating (seeSpecifications).Use equipment of adequate capacity to lift andsupport unit.

If using lift forks to move unit, be sure forks are long enough toextend beyond opposite side of unit.Follow the guidelines in the Applications Manual for the RevisedNIOSH Lifting Equation (Publication No. 94 110) when manu-ally lifting heavy parts or equipment.

HOT PARTS can burn.Do not touch hot engine parts bare-handed.

Allow cooling period before working onequipment.To handle hot parts, use proper tools and/orwear heavy, insulated welding gloves andclothing to prevent burns.

TILTING OR TIPPING can injure.Do not put any body part under unit while lifting.

Always use proper equipment (hoists, slings,chains, blocks, etc.) of adequate capacity to liftand support components (stator, rotor, engine,etc.) as needed during job.

PINCH POINTS can injure.Be careful when working on stator and rotor assemblies.

EXPLODING PARTS can injure.

Failed parts can explode or cause other parts toexplode when power is applied to inverters.

Always wear a face shield and long sleeveswhen servicing inverters.

H.F. RADIATION can cause interference.

High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.Have only qualified persons familiar with elec-tronic equipment perform this installation.

The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.If notified by the FCC about interference, stop using the equip-ment at once.Have the installation regularly checked and maintained.Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

OVERUSE can cause OVERHEATING.

Allow cooling period; follow rated duty cycle.Reduce current or reduce duty cycle beforestarting to weld again.Do not block or filter airflow to unit.

SHOCK HAZARD from testing.Stop engine or turn Off welding power source (if applicable) before making or changing meterlead connections.Use at least one meter lead that has a self-retaining spring clip such as an alligator clip.Read instructions for test equipment.

MAGNETIC FIELDS can affect ImplantedMedical Devices.

Wearers of Pacemakers and other ImplantedMedical Devices should keep away from serv-icing areas until consulting their doctor and thedevice manufacturer.

READ INSTRUCTIONS.

Use Testing Booklet (Part No. 150 853) whenservicing this unit.Consult the Owners Manual for welding safetyprecautions.

Use only genuine replacement parts from the manufacturer.Read and follow all labels and the Technical Manual carefully be-fore installing, operating, or servicing unit. Read the safety in-formation at the beginning of the manual and in each section.Reinstall injectors and bleed air from fuel system according toengine manual.

HYDRAULIC EQUIPMENT can injureor kill.

Before working on hydraulic system, turn off and lockout/tagout unit, release pressure, andbe sure hydraulic pressure cannot be accident-ally applied.

Do not work on hydraulic system with unit running unless you are aqualified person and following the manufacturers instructions.Do not modify or alter hydraulic pump or manufacturer-suppliedequipment. Do not disconnect, disable, or override any safetyequipment in the hydraulic system.Keep away from potential pinch points or crush points created byequipment connected to the hydraulic system.Do not work under or around any equipment that is supported onlyby hydraulic pressure. Properly support equipment by mechanicalmeans.

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HYDRAULIC FLUID can injure or kill.

Before working on hydraulic system, turn off andlockout/tagout unit, release pressure, and be surehydraulic pressure cannot be accidentally applied.Relieve pressure before disconnecting or con-necting hydraulic lines.

Check hydraulic system components and all con-nections and hoses for damage, leaks, and wearbefore operating unit.Wear protective equipment such as safetyglasses, leather gloves, heavy shirt and trousers,high shoes, and a cap when working on hydraulicsystem.

Use a piece of paper or cardboard to search for leaks never usebare hands. Do not use equipment if leaks are found.HYDRAULIC FLUID is FLAMMABLEdo not work on hydraulicsnear sparks or flames; do not smoke near hydraulic fluid.Reinstall doors, panels, covers, or guards when servicing isfinished and before starting unit.If ANY fluid is injected into the skin, it must be surgically removedwithin a few hours by a doctor familiar with this type of injury or gan-grene may result.

COMPRESSED AIR EQUIPMENT caninjure or kill.

Before working on compressed air system, turnoff and lockout/tagout unit, release pressure,and be sure air pressure cannot be accidentallyapplied.

Do not work on compressed air system with unit running unlessyou are a qualified person and following the manufacturers in-structions.Do not modify or alter compressor or manufacturer-suppliedequipment. Do not disconnect, disable, or override any safetyequipment in the compressed air system.Keep away from potential pinch points or crush points created byequipment connected to the compressed air system.Do not work under or around any equipment that is supported onlyby air pressure. Properly support equipment by mechanicalmeans.

COMPRESSED AIR can injure or kill.

Before working on compressed air system,turn off and lockout/tagout unit, release pres-sure, and be sure air pressure cannot be acci-dentally applied.Relieve pressure before disconnecting or con-necting air lines.

Check compressed air system componentsand all connections and hoses for damage,leaks, and wear before operating unit.

Do not direct air stream toward self or others.Wear protective equipment such as safety glasses, hearing pro-tection, leather gloves, heavy shirt and trousers, high shoes, anda cap when working on compressed air system.

Use soapy water or an ultrasonic detector to search forleaks never use bare hands. Do not use equipment if leaks arefound.Reinstall doors, panels, covers, or guards when servicing isfinished and before starting unit.If ANY air is injected into the skin or body seek medical help im-mediately.

1-3. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of California tocause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or otherreproductive harm. Wash hands after handling.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State ofCalifornia to cause cancer, birth defects, or other reproduc-tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents areknown to the State of California to cause cancer, birthdefects, and other reproductive harm.

1-4. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric 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 suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: The body of evidence, in thecommittees 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 beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.

To reduce magnetic fields in the workplace, use the followingprocedures:

1. Keep cables close together by twisting or taping them, or using acable cover.

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 Implanted Medical Devices:Implanted Medical Device wearers should consult their doctor and thedevice manufacturer before performing or going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heating operations.If cleared by your doctor, then following the above procedures is recom-mended.

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SECTION 2 DEFINITIONS

2-1. Warning Label Definitions

3/96

1 Remove unit from shippingcrate. Remove OwnersManual 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 forexpansion.

4 Warning! Watch Out! Thereare possible hazards asshown by the symbols. ReadOwners Manual. Followinstructions to activatebattery.

5 Check oil level. Add oil if necessary.

6 During the first 50 hours of operation, keep welding loadabove 200 amperes. Do notweld below 200 amperes of output.

7 After the first 50 hours of operation, change the oil andoil filter.

+2

1

+

4

DIESEL

API CD-MIL L 2104D,CD/SE, CD/SF

3

S-177 571

0 50 h Std. 0 200A200A

5

50 h Std.

Notes

Work like a Pro!Pros weld and cut

safely. Read thesafety rules atthe beginningof this manual.

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2-2. Manufacturers Rating Label

228 417-B / 803 562-F

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3-3. Volt-Ampere Curves

217 517 / 217 516 / 217 518

The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities of the welding generator. Curves of allother settings fall between thecurves 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

100908070605040302010

0

MINMAX300

0 100 200 300 400 500

100

80

60

40

20

0

D C V O L T S

DC AMPERES

D C V O L T S

DC AMPERES

0 100 200 300 400 500

100

80

60

40

20

0

MIN MAX300

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3-4. Fuel ConsumptionThe curve shows typical fuel useunder 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

3-5. Duty Cycle And Overheating

1 100% Duty CycleDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.

This unit is rated for welding at 250 amperes continuously.

NOTICE Exceeding duty cyclecan damage unit and void warranty.

217 515

10 15 20 25 30 40 50 60 80 100

CCCV

1000

800

600500

400

300250200

150

100

W E L D

A M P E R E S

% DUTY CYCLE

1

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3-6. AC Generator Power Curve

217 519

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

0 40 80 120 160

0 20 40 60 80

AC AMPERES IN 120 V MODE

AC AMPERES IN 240 V MODE

300

250

200

150

100

50

0

150

125

100

75

50

25

0

A C V O L T S

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

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4-2. Mounting Welding Generator

Tools Needed:9/16 in

2

2

4

Welding Unit In Place

Bolting Unit In Place

! Do not weld on base. Weld-ing on base can cause fueltank fire or explosion. Weldonly on the four mountingbrackets or bolt unit down.

NOTICE Do not mount unit by supporting the base only at the four mounting brackets. Use cross- supports to adequately support unit

and prevent damage to base.Mounting Surface:

1 Cross-Supports2 Mounting Brackets (Supplied)Mount unit on flat surface or usecross-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 tobase with original hardware.

Mount unit to truck or trailer with 1/2in (12 mm) or larger hardware (notsupplied).

To Weld Unit In Place:

Weld unit to truck or trailer only atthe four mounting brackets.

1

Inadequate support.

2

Supporting The Unit

Using Mounting Brackets

install3 2007 04 803 274 / 200 864-A / 803 562

! Do not use flexible mounts.

1

OR

3

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4-3. Installing Exhaust Pipe

1/2 in

Tools Needed:

803 582 / Ref. 217 357-A

! Stop engine and let cool.

Point exhaust pipe in desired direction but always away from front panel and direction of travel.

Notes



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4-4. Activating The Dry Charge Battery (If Applicable)

! Always wear a face shield,rubber gloves and protectiveclothing when working on abattery.

Remove battery from unit.5 Vent Caps6 Sulfuric Acid Electrolyte

(1.265 Specific Gravity)

7 WellFill each cell with electrolyte tobottom of well (maximum).

! Do not overfill battery cells.Wait ten minutes and check electro-lyte level. If necessary, add electro-lyte to raise to proper level. Reins-tall vent caps.8 Battery Charger

! Read and follow all instruc-tions supplied with batterycharger.

Charge battery for 12 minutes at 30amperes or 30 minutes at 5 am-peres. Disconnect charging cablesand 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

+

! Connect Negative ( ) Cable Last.

Tools Needed:

803 563 / Ref. 217 357-A / S-0756-C

Close door after connecting battery.

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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 beforethe 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 exhaustpipe during run-in, see Section 12.Fuel

NOTICE Do not use gasoline. Gasolinewill damage engine.The unit is shipped with enough fuel to pre-vent air from entering fuel system. Add freshdiesel fuel before starting (see engine main-tenance label for fuel specifications). Leavefiller neck empty to allow room forexpansion.

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 bottomof filler neck.

Check coolant level in recovery tank daily.If necessary, add coolant to recovery tankuntil coolant level is between Cold Full andHot Full levels. If recovery tank coolant levelwas 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 freeof dirt.

NOTICE Incorrect engine temperaturecan damage engine. Do not run engine with-out a properly working thermostat and ra-

diator 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 7-2 ).

Full

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

803 563

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4-7. Connecting To Weld Output Terminals

803 562 / 803 778-A

Tools Needed:

3/4 in

MIG and FCAW WeldingFor MIG and FCAW welding Direct CurrentElectrode Positive (DCEP) connect wire feed-er cable to CV (Wire) terminal on right andwork cable to Work/Negative ( ) terminal onleft. Use Process/Contactor switch to selecttype of weld output (see Section 5-3).

For Direct Current Electrode Negative

(DCEN), reverse cable connections.

7

5

6

Do not placeanything between

Correct Installation Incorrect Installation

4

weld cable terminaland copper bar.

! Stop engine.1 Work/Negative ( ) Weld Output Terminal

2 CV (wire) Weld Output Terminal

3 CC (Stick/TIG) Weld Output Terminal

! Failure to properly connect weldcables may cause excessive heat andstart a fire, or damage your machine.

4 Weld Output Terminal5 Supplied Weld Output Terminal Nut6 Weld Cable Terminal7 Copper BarRemove supplied nut from weld output termi-nal. Slide weld cable terminal onto weld outputterminal and secure with nut so that weld cableterminal is tight against copper bar. Do notplace 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 WeldingFor Stick and TIG welding Direct Current Elec-trode Positive (DCEP), connect electrodeholder cable to CC (Stick/TIG) terminal onright and work cable to Work/Negative ( ) ter-minal on left.

For Direct Current Electrode Negative(DCEN), reverse cable connections.

Use Process/Contactor switch to select typeof weld output (see Section 5-3).

1

23

1 2 3

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4-8. Selecting Weld Cable Sizes*

Weld OutputTerminals

! Stop engine beforeconnecting to weld

output terminals.! Do not use worn, dam-

aged, undersized, orpoorly spliced cables.

Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot 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)

WeldingAmperes

10 60%Duty

Cycle

60 100%Duty

Cycle10 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.

( ) = mm2 for metric use S-0007-F

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

Notes

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4-9. Connecting To Remote 14 Receptacle RC14

OR

LDR-14 longdistance remote(includes 120 V

receptacle)

803 562

Socket* Socket Information

24 VOLTS AC

A 24 volts AC. Protected by sup-plementary protector CB8.

B Contact closure to A completes24 volt AC contactor controlcircuit.

REMOTEOUTPUT

CONTROL

C Output to remote control:+10volts DC in MIG mode; 0 to +10volts DC in Stick or TIG mode.

D Remote control circuit common.

E DC input command signal: 0 to+10 volts from min. to max. of remote control with Voltage/

Amperage Adjust control atmax.

115 VOLTS ACI

115 volts, 10 amperes, 60 Hz AC. Protected by supplementa-ry protector CB7.

JContact closure to I completes115 volt AC contactor controlcircuit.

F Current feedback: 1 volt per100 amperes.

H Voltage feedback: 1 volt per 10arc volts.

GND K Chassis common.

NEUTRAL G Circuit common for 24 and 115volt AC circuit.

*The remaining sockets are not used.

Notes



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Notes

Welding SymbolsRef. AWS/ANSI A2.4

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SECTION 5 OPERATING WELDING GENERATOR

5-1. Front Panel Controls (See Section 5-2 )

217 357-B / 803 563

1 2 546

7 89 10

3

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5-3. Process/Contactor Switch1 Process/Contactor Switch

! Weld output terminals are ener-gized when Process/Contactorswitch is in a Weld Terminals Al-ways On position and the engineis running.

Use switch to select weld process andweld output on/off control (see table be-low).

Place switch in Remote On/Off SwitchRequired positions to turn weld output onand off with a device connected to theRemote 14 receptacle.

Place switch in Weld Terminals AlwaysOn positions for weld output to be onwhenever the engine is running.

Use Stick mode for air carbon arc(CAC-A) cutting and gouging.

When switch is in Stick mode, select oneof four arc drive (dig) settings to provideadditional amperage during low voltage(short arc length) conditions and preventsticking electrodes. Turn control from Ato D to increase arc drive (dig) from minto max.

Use the Lift-Arc TIG mode for TIG(GTAW) welding using the Lift-Arc TIGstarting procedure (see Section 5-4).

1

803 562 / 217 357

Process/Contactor Switch Settings

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, PulsingDevice, Or Remote Control At Remote 14 Receptacle Active

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

Remote On/Off SwitchRequired CV Feeder

Using Remote

MIG (GMAW)w/Constant Speed Feeder At Remote 14 Receptacle Active

Weld Terminals Always On Wire

MIG (GMAW)w/Voltage Sensing Feeder Electrode Hot Active

Weld Terminals Always On Stick

Stick (SMAW), Air Carbon Arc (CAC-A) Cutting

And GougingElectrode Hot Active

Weld Terminals Always On TIG Lift-Arc TIG Lift-Arc (GTAW) Electrode Hot Active

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5-4. Lift-Arc Start Procedure

Lift-Arc TIG

With Lift-Arc TIG selected, startarc as follows:

1 TIG Electrode

2 Workpiece

Turn gas on. Touch tungstenelectrode to workpiece at weld startpoint. Hold electrode to

workpiece for 1-2 seconds , andslowly lift electrode. Arc is formedwhen electrode is lifted.

Normal open-circuit voltage is notpresent before tungsten electrodetouches workpiece; only a lowsensing voltage is present betweenelectrode and workpiece. Thesolid-state output contactor doesnot energize until after electrode istouching workpiece. This allowselectrode to touch workpiecewithout overheating, sticking, or be-ing contaminated.

Application:

Lift-Arc is used for the DCENGTAW process when HF Startmethod is not permitted, or toreplace the scratch method.

1

1 2SecondsTouch

Do NOT Strike Like A Match!

2Lift-Arc Start Method

Notes

Work like a Pro!Pros weld and cutsafely. Read the

safety rules atthe beginningof this manual.

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5-5. Remote Voltage/Amperage Control

1 Remote 14 Receptacle RC14Connect optional remote control to RC14 (seeSection 4-9).

When a remote control is connected to theRemote receptacle, the Auto Sense Re-

mote feature automatically switches voltage/amperage control to the remote con-trol. When a device is connected to the Re-

mote receptacle, remote voltage/amperage control is always available regardlessof the position of the Process/Contactor

switch.

0774 / Ref.217 357 B / 803 562

Adjust Optional RemoteControl to 100%

Set V/A ControlTo Desired Maximum

Weld Output Using WeldMeters

Set TIG or STICK Process

In Example:Min = 20 A DC

Max = 205 A DC

Max (205 A DC)

Min (20 A DC)

Connect RemoteControl To RemoteReceptacle RC14

1

Adjust Optional Remote Control to desired

weld output

Weld meters will alwaysshow the combined mainand remote controlsetting; machine welds atnominal output setting of the meter.Weld meters show presetoutput when not welding.

Set WIRE Process

Connect RemoteControl To RemoteReceptacle RC14

Adjust Optional Remote Control to desired

weld output

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SECTION 6 OPERATING AUXILIARY EQUIPMENT

6-1. Generator Power Receptacles

217 357-A

1 120 V 20 A AC (shown)Receptacle RC5 and/or GFCI1

2 120 V 20 A AC GFCI (shown)Receptacle RC6 and/or GFCI2

3 240 V 50 A ACReceptacle RC11

RC5 / 6 and GFCI1 / 2 supply 60 Hz single-phase power at weld/power speed. Recep-tacle configuration varies depending onmachine model and serial number.

Maximum output from these receptacles is2.4 kVA/kW.

If a ground fault is detected, GFCI Resetbutton pops out and receptacle does notwork. Check for faulty equipment plugged

in receptacle. Press button to reset GFCIreceptacle.

At least once a month, run engine at weld/power speed and press test but-ton to verify GFCI is working properly.

RC11 supplies 60 Hz single-phase powerat weld/power speed. Maximum outputfrom RC11 is 10 kVA/kW.

4 Supplementary Protector CB4



CB4 protects RC6 / GFCI2 and CB6 pro-tects RC5 / GFCI1 from overload. If a sup-plementary protector opens, the receptacledoes not work. Press button to reset.

Supplementary protector CB5 protects re-ceptacles and the generator winding fromoverload. If CB5 opens, the receptacles do

not work. Place CB5 switch in On positionto reset circuit breaker.

Generator power decreases as weld output increases.

Combined output of all receptacles is limit-ed to the 10 kVA/kw rating of the generator.

EXAMPLE: If 15 A is drawn from each 120V receptacle , only 26 A is available at the240 V receptacle:

2 x (120 V x 15 A) + (240 V x 26 A) =10.0 kVA/kW

1 2 3 4 5 6

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SECTION 7 MAINTENANCE7-1. Routine Maintenance

! 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 enginefluids.

= Check = Change = Clean = Replace * To be done by Factory Authorized Service Agent Reference

Every8Hours

Section 4-6,7-8

Coolant Level Fuel Level Oil Level Oil, Fuel Spills

Every50Hours

Weld Terminals

Every100

Hours

Section 7-3

Battery Terminals Air Cleaner Hoses Air Cleaner Element

Every250Hours

1/2 in.(13 mm)

EngineManual,Section 7-4

Unreadable Labels Fan Belt Tension Oil Oil Filter Spark Arrestor

Every500Hours

Weld Cables Fuel Filter Inline Fuel Filter Radiator Thermostat

Every1000Hours OR

SLUDGE

FUEL Section 4-6,7-10 , 7-8and EngineManual

Radiator Fluid Level Inside Unit Valve Clearance* Drain Sludge

Slip Rings*Brushes*

Every2000Hours

Injectors*

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7-2. Maintenance Label

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7-3. Servicing Air Cleaner

! Stop engine. NOTICE Do not run engine without air cleaner or with dirty element. Enginedamage caused by using a damaged ele-

ment is not covered by the warranty.

The air cleaner primary element can be cleaned but the dirt holding capacity of the filter is reduced with eachcleaning. The chance of dirt reachingthe 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 element, we strongly recommend installing an optional safety element to pro-vide additional engine protection.

Never clean a safety element. Re- place the safety element after servicing 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 sixcleanings.

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 capand dump out dust. Remove element(s).Wipe dust from inside cap and housing

with damp cloth. Reinstall safety element(if present). Reinstall cap.

NOTICE Do not clean housing with air hose.

Clean primary element with compressedair only.

Air pressure must not exceed 100 psi(690 kPa). Use 1/8 in (3 mm) nozzle andkeep nozzle at least 2 in (51 mm) frominside of element. Replace primary ele-ment if it has holes or damaged gaskets.

Reinstall primary element and cap (dustejector down).

Blow Inspect

41 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. 217 357-A

Optional

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7-4. Inspecting And Cleaning Optional Spark Arrestor Muffler

803 582 / Ref. 214 778-B

! Stop engine and let cool.1 Spark Arrestor Muffler

2 Cleanout Plug

Remove plug and remove any dirtcovering cleanout hole.

3 Exhaust Pipe

Start engine and run at idle speed toblow out cleanout hole. If nothingblows out of hole, briefly cover endof exhaust pipe with fireproof material.

! Stop engine and let cool.Reinstall cleanout plug.

Tools Needed:

3/8 in

1

2

3

7-5. Servicing Engine Cooling System

803 563

! Stop engine and let cool.1 Radiator Draincock2 Radiator Cap Cover

Change coolant according to enginemanual. Add coolant according to Sec-tion 4-6).

Run engine until engine reaches normaloperating temperature. Check coolantlevel in recovery tank. Add coolant if nec-essary.

After engine cools, check coolant levelagain and add coolant if necessary.

1

2

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7-6. Adjusting Engine Speed On Standard Models

803 563-E

3

1

2

RPM (Hz)Engine Speed

(No Load)

Weld/Power 1880 (61.7)Maximum

! Stop engine and let cool.Engine speed is factory set andshould not require adjustment. Af-ter tuning engine, check enginespeed with tachometer or frequen-cy meter. See table for proper noload speed. If necessary, adjustspeed as follows:

Start engine and run until warm.Turn Process/Contactor switch toWeld Terminals Always On Stickposition.1 Lock Nut2 Adjustment ScrewLoosen nut. Turn screw until engineruns at weld/power speed. Tightennut.

Do not set engine speed higher than specified. Tampering with

adjustments other than shown may affect engine warranty

3 Engine Stop Lever

! Stop engine.Close door.

Tools Needed:

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7-7. Adjusting Engine Speed On Models With Automatic Idle (Optional)

803 563-G

1880 rpm max(62.6 Hz)

1500 rpm(50 Hz)

Engine Speed(No Load)

1

2

3

4

To prevent solenoid damage, be sure a 1/8

in (3 mm) gap exists be-

tween the engine low speed screw and throttle lever when the

solenoid is held in theenergized position.

Engine Speed Adjustment

After tuning engine, check en-gine speed with tachometer orfrequency meter. See table forproper no load speed. If neces-sary, adjust speed as follows:

Start engine and run until warm.Turn Process/Contactor switch

to Stick

Weld Terminals Al-ways On position.1 Throttle Rod / Plunger

2 Lock Nut

3 Rubber Boot

4 Adjustment Screw

Adjustment screw is not used toadjust engine speed when auto-matic idle option is installed.However, it must be at least 1/8in (3 mm) away from the throttlearm when engine is running atidle rpm.

Unhook rubber boot from the so-lenoid housing but leave con-nected to plunger.Loosen lock nut. Place EngineControl Switch in Auto position.

Turn throttle rod and plunger un-til engine runs at idle speed.Tighten lock nut.

Hook rubber boot back onto so-lenoid housing.

Be sure solenoid plunger pulls all the way in (bot-toms) when energized.

Weld/Power SpeedAdjustment

Weld/power speed adjustment must be done by theengine manufacturers fac-tory authorized service

agent.Tampering with adjustmentsother than shown may affect engine warranty.

! Stop engine.

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7-8. Servicing Fuel And Lubrication Systems

802 490 / Ref. 801 434

! Stop engine and let cool.! After servicing, start engine

and check for fuel leaks.Stop engine, tighten connec-tions as necessary, and wipeup spilled fuel.

1 Oil Filter2 Oil Drain Valve And Hose3 Oil Fill Cap4 Primary (Canister) Fuel Filter

5 Secondary (In-Line) FuelFilter

6 Fuel Tank Sludge Drain Valve

To change oil and filter:

Route oil drain hose and valvethrough hole in base. See enginemanual and engine maintenancelabel for oil/filter change in-formation.

To replace primary (canister) fuelfilter:

Turn filter counterclockwise. Re-move filter.

Fill new filter with fresh fuel. Applythin 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, andreinstall clamps.

To drain sludge from fuel tank:

! Beware of fire. Do not smokeand keep sparks and flamesaway from drained fuel. Dis-pose of drained fuel in an en-vironmentally-safe manner.Do not leave unit unattendedwhile draining fuel tank.

! Properly lift unit and securein a level position. Use ade-quate blocks or stands tosupport unit while drainingfuel tank.

Attach 1/2 ID hose to drain valve.Put metal container under drain,and use screwdriver to opensludge drain valve. Close valvewhen sludge has drained. Removehose.

Close door. Tools Needed:

6

3

5

2

4

1

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7-9. Overload Protection

! Stop engine.1 Fuse F1F1 protects the stator exciter wind-ing from overload. If F1 opens, weldand generator power is low or stopsentirely.

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)3 Supplementary Protector CB24 Supplementary Protector CB3



7 Circuit Breaker CB9

CB1 protects the engine battery cir-cuit. If CB1 opens, the engine will notcrank. CB1 automatically resetswhen the fault is corrected. If CB1continues 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 and PC3.

CB2 protects the engine wiring har-ness. If CB2 opens, the engine willnot crank. Press button to resetbreaker. If CB2 continues to open,check fuel solenoid FS1, the fuelpump, throttle solenoid TS1, inte-grated rectifier SR1, and circuitboards PC2 and PC3.

CB3 protects part of the weld controlwiring harness. If CB3 opens, weldand generator power output stops. If CB3 continues to open, check circuitboards PC1, PC2, and PC3.

CB7 protects the 115 volt AC outputto remote receptacle RC14. If CB7opens, 115 volt output to RC14stops. If CB7 continues to open,check remote controls connected toRemote receptacle RC14, and cir-cuit board PC6.

CB8 protects the 24 volt AC output toremote receptacle RC14. If CB8opens, 24 volt output to RC14 stops.If CB8 continues to open, check re-mote controls connected to Remotereceptacle RC14, and circuit boardPC6.

CB9 protects the throttle solenoidagainst overload. If CB9 opens, theengine does not automatically idledown. Check the linkage and sole-noid. CB9 automatically resets.

803 562 / 803 566

1

5 6

3

4

7

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7-10. Checking Generator Brushes

Ref 2114 778 D / S 0233 A

! Stop engine and let cool.1 Generator Brush With Spring

Mark and disconnect leads at brush hold-er cap. Remove brushes.

Replace brushes if damaged or if brushmaterial is at or near minimum length.

1

5/16 in. (8 mm)Minimum Length

9/16 in. (14.3 mm)New Length

ReplaceDamaged Brushes

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

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7-11. 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

803 562 / 217 357-A

When a help code is displayed, normally weld output has stopped but generator power output may be okay. Auxiliary power must be available and correct be-fore continuing. If auxiliary output

is not correct, disregard helpcodes until auxiliary power prob-

lem is corrected. If both weld output and auxiliary power are not available, see Section 9-7 for module testing information.

Use the Voltmeter/Ammeter helpdisplays to diagnose and correctfault conditions.

To reset help displays, stopunit and then restart. See item6 below to reset Help 25 dis-

play.

1 Help 20 DisplayIndicates a failure of meter displaymodule PC2, or the wiring betweenPC2 and main control module PC1.If this display is shown, check PC1,PC2, and the wiring between PC1and PC2.2 Help 21 DisplayIndicates thermistor TH1 on themain rectifier heat sink has failed.If this display is shown, check TH1,and the wiring between TH1 andPC1.3 Help 22 DisplayIndicates the rectifier heat sink has

overheated. If this display is shown,check generator cooling systemand/or reduce duty cycle. Keep en-gine access door closed when run-ning to maintain proper cooling airflow past rectifier. Allow unit to coolbefore restarting.4 Help 23 DisplayIndicates one of the rectifier outputSCRs has failed. If this display isshown, check the rectifier SCRs.5 Help 24 DisplayVerify engine speed is correct bychecking frequency at 115 volt ACduplex receptacle (should beapproximately 62 Hertz with EngineControl switch in the Run position).If engine speed is correct and weldopen circuit voltage (OCV) is toohigh (above 41 volts DC), checkmain control module PC1.6 Help 25 DisplayIndicates a remote device con-nected to Remote ReceptacleRC14 may be faulty. Help 25 is alsodisplayed whenever a remote de-vice has been connected to RC14and then disconnected. Clear faultby stopping and restarting the unitor by turning Process/Contactorswitch to another position. If prob-lem continues, check the remote

device, filter board PC6, and maincontrol module PC1.

If no remote control device isplugged in to Remote receptacleRC14 and the corrective actionabove has been followed, discon-nect filter board PC6. If the helpcode is still displayed, main controlmodule PC1 may be at fault. If thehelp code clears, replace PC6.

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12 Control Board PC1Controls weld output by changingmain rectifier SCR gate pulses(conduction times) after comparingamperage (CC) or voltage (CV)feedback to selected voltage/am-perage signal.

13 Thermostat TH1Thermostat opens and stops allweld output if unit overheats.

14 Meter Board PC2Displays preset and actual (rectifiedand filtered) values of the weld volt-age and amperage.

15 Main RectifierChanges AC weld current to DC.

Works with PC1 (item 12) to con-trols weld output by changing recti-fier SCR gate pulses (conductiontimes) after comparing voltage (CV)or amperage (CC) feedback to se-lected voltage or amperage signal.

16 Burden Resistor R3Provides a path for a minimum SCRholding current to flow.

17 Hall Device HD1Provides current feedback signal toPC1.

18 Stabilizer Z1Smooths (filters) weld outputcurrent.

19 Capacitor Bank C10Filters the DC output voltage of main rectifier.

20 Work ( ), CC, And CV WeldOutput Terminals

Provide weld output and allowchanging of output polarity.

AC Or DC Control Circuits

Weld Current Circuit

External Circuits

Thermostat

13

TH1

SCRGatingSignals

17Hall Device

HD1

16

18

CurrentFeedback

StabilizerZ1

20

20

Electrode

Work

19

CapacitorBank C10

20

CC or CVVoltage

Feedback

MainRectifier

15

3

Power

CV WeldOutput

Terminal

CC WeldOutput

Terminal

Work ( ) WeldOutput

Terminal

11

Process/ ContactorSwitch R1

14

MeterBoard PC2

10

Voltage/ AmperageControl R2

CC

CVBurden

Resistor R3

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B. Engine/Generator Training Circuit

This circuit is for training purposesonly. It has been modified for that useand may not reflect the actual circuitfor your unit.

Reference:DC common - lead 42Unless otherwise noted

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Training 219 228

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SECTION 9 TROUBLESHOOTING

9-1. Troubleshooting Tables

See Section 9-2 for test points and values and Section 13 and followingfor parts location.

Use MILLER Testing Booklet (Part No. 150 853) when servicing thisunit.

Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (see Section 7-11 ).

A. Welding

Trouble Remedy

No weld output; generator power outputokay at AC receptacles.

Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a RemoteOn/Off Switch Required position and turn remote contactor on (see Section 4-9 ).

Reset supplementary protector CB7 or CB8 (see Section 7-9). Check for faulty remote device connectedto 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 properconnections. Replace Z1 if necessary.

Check Voltmeter/Ammeter help displays (see Section 7-11 ).

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 7-9).

Check fuse F1, and replace if open (see Section 7-9). If F1 is open, check the voltage regulator boardPC3. (If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output.

Check rotor and brushes before replacing PC3.)Check Voltmeter/Ammeter help displays (see Section 7-11 ).

Check control relay CR1 for proper coil voltage and connections. Check continuity of coil. Replace CR1if necessary.

Clean slip rings, and install new brushes if necessary (see Section 9-15 ).

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.

Check voltage regulator board PC3 and connections, and replace PC3 if necessary (see Section 9-10 ).(If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check rotorand brushes before replacing PC3.)

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

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

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.

High weld output (Continued). Check hall device HD1, and replace if necessary (see Section 9-2).

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Trouble Remedy

Check main control board PC1 and connections, and replace PC1 if necessary.

Low weld output. Check engine speed, and adjust if necessary.

Increase Voltage/Amperage Adjust control R2 setting.

Check fuse F1, and replace if open (see Section 7-9).

Repair or replace remote control device.


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

Check main control board PC1 and connections, and replace PC1 if necessary.


Check SCRs in main rectifier, and replace if necessary. If any SCRs are replaced, check capacitorsC1 through C9 for a short or open, and check for proper connections. Replace C1 through C9 ifnecessary.

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 or 115 volt AC output at Re-mote receptacle RC14.

Reset supplementary protector CB7 (24 volt) or CB8 (115 volt) (see Section 7-9).

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 6-1).

Check resistance of generator power windings between leads 91 and 92. Replace stator ifnecessary.

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

Check fuse F1, and replace if open (see Section 7-9). If F1 is open, check the voltage regulator boardPC3 (see Section 9-10 ). (If PC3 senses an overload condition (shorted rotor), it protects itself by stoppingweld output. Check rotor and brushes before replacing PC3.)


Check Voltmeter/Ammeter help displays (see Section 7-11 ).

Check control relay CR1 for proper coil voltage and connections. Check continuity of coil. Replace CR1if necessary.

Clean slip rings, and install new brushes if necessary (see Section 9-15 ).


Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator if necessary.


High output at generator power acreceptacles.


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Trouble Remedy

Low output at generator power ACreceptacles.

Check engine speed, and adjust if necessary.

Check fuse F1, and replace if open (see Section 7-9). If F1 is open, check the voltage regulator boardPC3 (see Section 9-10 ). (If PC3 senses an overload condition (shorted rotor), it protects itself by stoppingweld output. Check rotor and brushes before replacing PC3.)

C. Engine

Trouble RemedyEngine 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 7-9 ).Check engine wiring harness and components.


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 conditionof 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. ReplaceFS1 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 5-1).

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

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

Use correct grade oil for cold weather (see Section 7-2).

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 coolanttemperature is too high (see Section 4-6 ).

Reset circuit breaker CB1 and/or CB2 (see Section 7-9). Check engine alternator, engine harness,throttle solenoid TS1, fuel solenoid FS1, and the fuel pump.

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. ReplaceFS1 if necessary.


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Trouble Remedy

Check fuel pump according to engine manual.

Check engine wiring harness and plug connections.

See engine manual.

Engine slowly stopped and cannot berestarted.

Check fuel level.

Check engine air and fuel filters (see Sections 7-3 and 7-8).

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 toweld speed (units with idle option only).

Check for obstructed throttle solenoid TS1

Eff w/ LG440030E: Circuit breaker CB9 may be open. CB9 automatically resets when the fault iscorrected. Check for obstructed throttle solenoid TS1 and check TS1 voltage.

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 12).

Notes

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9-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 9-3 )

I1

Glow plugrelay CR3

Starter controlrelay CR2

Throttle SolenoidTS1 (Pull To Idle)

V6,

V7,R7

R6

Idle controlrelay CR4

Enginecontrol

relay CR1

See Section 9-10 forPC3 data

V1,R1

V2,R2

V4,R4

V5,R5

V8,R8

V9,R9

R13

V10,R10

V11,R11

V12

R12

V23

V24

V25

V26

E

V3,R3

See Section9-12 for PC2

data

See Section 9-14for PC5 data

EE

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219 228-E

See Section 9-4for waveforms

A,B,C,D,E

See Section9-5 for

PC6 data

See Section4-9 for RC14information

V13, R14 V14 V15 V16

V17,A,C

V18,B,D

V20

E EE

EE E

V21 V22 V19

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9-3. Troubleshooting Values For Circuit Diagram (Use With Section 9-2 )

Voltage Readings

a) Tolerance 10% unless specified

b) Condition

70 F (21 C); cold machine(no warm-up); no load; weld/power rpmunless noted

c) Reference single arrow: reference tocircuit common (lead 42); doublearrow: reference to points indicated

d) Process/Contactor switch R1 in WeldTerminals Always On Stick (Dig-B)position unless noted

e) Wiring Connections see Section 11

V1 120 124 volts ac

V2 120 124 volts ac

V3 240 248 volts ac

V4 158 volts acV5 24 volts acV6 46 volts ac

V7 46 volts ac

V8 46 volts ac

V9 + 61 volts DC

V10 +12 volts DC

V11 +12 volts DC

V12 +12 volts DC

V13 0 to +5 volts DC from Weld Terminals Always On Wire position to Remote Wireposition of Process Contactor switch R1 (in0.45 volt increments)

V14 +5 volts DCV15 0 to +5 volts DC from min to max of

Voltage/Amperage control R2

V16 +5 volts DC

V17 With Process/Contactor switch R1 in WeldTerminals Always On TIG position +20volts DC; with R1 in Stick position:Prior to LH030117E: +41 volts DCEff w/LH030117E: +57 volts DC

V18 14 to +40 volts DC with Process/Contactorswitch R1 in Weld Terminals AlwaysOnWire position

V19 Circuit common

V20 1 volt DC per 100 amperes of weld output

V21 15 volts DC

V22 +15 volts DC

V23 +12 volts DC

V24 +12 volts DC input with Engine Controlswitch S1 in Start position

V25 +12 volts DC input with Engine Controlswitch S1 in Start or Run position

V26 Ground path for CR1:Normal operation: 0 volts DCFault shutdown: +12 volts DC

Test Equipment Needed:

Amperage Readings

a) Tolerance 5% unless specified

b) Condition 70 F (21 C); coldmachine (no warm-up); no load;weld/power rpm unless noted

c) Process/Contactor switch R1 inWeld Terminals Always On Stick(Dig-B) position unless noted

I1 3.1 amps DC4.6 amps at 20 volt, 200 amp load

Resistance Values

a) Tolerance 10% unlessspecified

b) Condition 70 F (21 C); coldmachine (no warm-up)

c) Wiring Connections seeSection 11

d) Stop engine before checkingresistance

R1 thru R8 Less than 1 ohmR9 22 ohmsR10 14.2 ohmsR11 Throttle plunger pulled in

0.6 ohmsThrottle plunger extended 17 ohms

R12 Empty fuel tank: 250 ohmsFull tank: 0 ohms

R13 30 Kohms cold, drops as unit heats up

R14 Increases in 1 Kohmincriments up to 11 Kohms,then resets to zero.

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Notes

BUTTBUTTBUTT

BUTT

TJOINT TJOINT

TJOINT TJOINT

FILLET

GROOVE

FLAT VERTICALHORIZONTAL OVERHEADWELD POSITION:

WELD JOINTTYPES

Ref. AWS/ANSI D1.1

1G

1F

2G

2F

3G

3F

4G

4F

Ref. 804 248-A

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9-4. Waveforms For Sections 9-2

2 ms 50 V

A. Prior to LH030117E: CC/DC Open-Circuit Volt-age, Process/Contactor Switch R1 In WeldTerminals 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 AlwaysOn 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.

2 ms 50 V

A. Eff w/LH030117E: CC/DC Open-Circuit Volt-age, Process/Contactor Switch R1 In WeldTerminals Always On Stick (Dig B) Position,


gnd

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E. SCR Gate Pulses w/Respect To Cathode At NoLoad, Process/Contactor Switch R1 In WeldTerminals Always On Stick (Dig B) Position,


5 ms 2 V

gnd

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

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, (ResistiveLoad)

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9-5. Filter Board PC6 Testing Information

803 702 / 217 008 / 805 517 A

! Stop engine.See Section 9-6 for specific valuesduring testing. Voltage readings tol-erance 10%.1 Filter Board PC62 Receptacle RC2

Test Equipment Needed:1

2

Prior to LH030117E

Eff w/LH030117E

1

2

9-6. Filter Board PC6 Test Point Values

PC6 Voltage Readings

a) Tolerance 10% unless specifiedb) Reference to circuit common (lead 42) unless notedc) Condition no load; weld/power rpm unless notedd) Process/Contactor switch S6 in Weld Terminals Always On Stick position

Receptacle Pin Value

RC2 1 Not used on this model

2 Not used on this model

3 Not used on this model

4 Voltage feedback: 1 volt DC per 10 arc volts

5 Circuit common for 24 and 115 volt AC contactor control circuits (Lead No. 80)

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 betweenpins A and B

8 Command common

9 Remote command signal input: 0 to +10 volts DC input from min to max of remote voltage/amperagecontrol

10 Current feedback: 1 volt DC per 100 arc amperes

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9-7. Module Testing Information

803 702

If there is no weld output and noauxiliary power output, use thistesting information to determinewhich circuit board module may beat fault.1 Main Control Board PC12 Receptacle RC63 Jumper WiresLocate 30 pin plug PLG6 and dis-connect from PC1 module RC6.Install jumper wires at the followingpins on PLG6:

G3 (Lead No. 117) to H3 (Lead No.113)

D2 (Lead No. 107) to J3 (Lead No.130)

Start engine with these jumpersinstalled and check for auxiliarypower.

If auxiliary power is present, PC1could be at fault. Use Sections 9-8and 9-9 to troubleshoot PC1.

If auxiliary power is not present,

Voltage Regulator board PC3 couldbe at fault. Be sure PC3 is supply-ing the following voltages at PC1module:4 Receptacle RC7Check for +14 volts DC at PLG7 pinE1 (lead no. 120)

Check for +15 volts DC at PLG6 pinE3 (lead no. 109)

Check for 15 volts DC at PLG6 pinF3 (lead no. 106).

Use Sections 9-10 and 9-11 to trou-bleshoot PC3.

Remove jumper wires before con-tinuing troubleshooting.

1

2

3

4

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9-8. Main Control Board PC1 Testing Information

803 702

! Stop engine.See Section 9-9 for specific valuesduring testing. Voltage readings tol-erance 10%.1 Main Control Board PC12 Plug PLG63 Plug PLG7

4 Plug PLG11


14

2

3

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9-9. Main Control Board PC1 Test Point Values



b) Reference to circuit common(lead 42) unless noted

c) Condition no load; weld/pow-er rpm unless noted

d) Process/Contactor switch R1

in Weld Terminals Always On

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 inputG3 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/amperagecontrol

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 On Wire position to Remote Wire position of ProcessContactor 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

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9-10. Voltage Regulator Board PC3 Testing Information

803 702

! Stop engine.See Section 9-11 for specific valuesduring testing. Voltage readings tol-erance 10%.1 Voltage Regulator Board PC32 Receptacle RC13 Receptacle RC2


1

2

3

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9-11. Voltage Regulator Board PC3 Test Point Values



b) Reference to circuit common(lead 42) unless noted

c) Condition no load; weld/pow-er rpm unless noted

d) Process/Contactor switch R1

in Weld Terminals Always On 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

2 120 volts AC input with respect to pin RC1-3

3 Not used

4 Not used

5 158 volts AC input with respect to pin RC2-86 +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

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9-12. Meter Display Board PC2 Testing Information

803 702 / 214 536

! Stop engine.See Section 9-13 for specific val-ues during testing. Voltage read-ings toleran

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BIG BLUE 300 P (LE099775)