Big Blue 400 CX

OM-4435 218 759N200805

Processes

Description

Air Carbon Arc (CAC-A)Cutting and Gouging

Stick (SMAW) Welding

Engine Driven Welding Generator

TIG (GTAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

File: Engine Drive

Visit our website at

www.MillerWelds.com

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you dont have time to doit any other way.

Thats why when Niels Miller first started building arc welders in 1929,he made sure his products offered long-lasting value and superiorquality. Like you, his customers couldnt afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.

Today, the people that build and sell Miller products continue thetradition. Theyre just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.

Weve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,theres a Troubleshooting section that willhelp you figure out what the problem is. Theparts list will then help you to decide theexact part you may need to fix the problem.Warranty and service information for yourparticular model are also provided.

Miller is the first weldingequipment manufacturer inthe U.S.A. to be registered tothe ISO 9001:2000 QualitySystem Standard.

Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

From Miller to You

Mil_Thank 4/05

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Compressed Air Hazards 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Additional Symbols For Installation, Operation, And Maintenance 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. California Proposition 65 Warnings 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7. Principal Safety Standards 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8. EMF Information 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Signification des symboles 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage larc 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers existant en relation avec le moteur 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. Dangers lis lair comprim 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance 9 . . . . . . 2-6. Proposition californienne 65 Avertissements 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. Principales normes de scurit 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8. Information EMF 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 DEFINITIONS 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Warning Label Definitions 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Symbols And Definitions 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 SPECIFICATIONS 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Weld, Power, And Engine Specifications 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Dimensions, Weights, And Operating Angles 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Volt-Ampere Curves 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Fuel Consumption 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Duty Cycle And Overheating 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. AC Generator Power Curve 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 INSTALLATION 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Installing Welding Generator 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Mounting Welding Generator 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Rating Label Location 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Installing Exhaust Pipe 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Activating The Dry Charge Battery (If Applicable) 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Connecting The Battery 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Engine Prestart Checks 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9. Connecting To Weld Output Terminals 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10. Selecting Weld Cable Sizes* 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11. Connecting To Remote 14 Receptacle RC14 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 OPERATING WELDING GENERATOR 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Front Panel Controls (See Section 6-2) 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Description Of Front Panel Controls (See Section 6-1) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Process/Contactor Switch 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Lift-Arc TIG With Crater-Out And Auto-Stop 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5. Remote Voltage/Amperage Control 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6. Fuel/Hour Gauge Descriptions 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 OPERATING AUXILIARY EQUIPMENT 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Auxiliary Power Receptacles 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 MAINTENANCE & TROUBLESHOOTING 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Maintenance Label 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Routine Maintenance 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Caterpillar Customer Assistance 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

8-4. Checking Generator Brushes 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5. Servicing Air Cleaner 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6. Inspecting And Cleaning Spark Arrestor Muffler 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7. Servicing Engine Cooling System 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8. Adjusting Engine Speed On Standard Models 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9. Adjusting Engine Speed On Models With Automatic Idle (Optional) 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10. Servicing Fuel And Lubrication Systems 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11. Overload Protection 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12. Optional Voltmeter/Ammeter Help Displays 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13. Troubleshooting 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 ELECTRICAL DIAGRAMS 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 RUN-IN PROCEDURE 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Wetstacking 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2. Run-In Procedure Using Load Bank 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Run-In Procedure Using Resistance Grid 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 GENERATOR POWER GUIDELINES 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTYSECTION 12 PARTS LIST 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

dec_rot_1/07

Declaration of Conformity forEuropean Community (CE) Products

This information is provided for units with CE certification (see rating label on unit).

Manufacturer: European Contact:Miller Electric Mg. Co. Mr. Danilo Fedolfi,1635 W. Spencer St. Managing DirectorAppleton, WI 54914 USA ITW Welding Products Italy S.r.l.Phone: (920) 734-9821 Via Privata Iseo 6/E

20098 San GiulianoMilanese, ItalyPhone: 39(02)98290-1Fax: 39(02)98290203

European Contact Signature:

Declares that the product: Big Blue 400 CXconforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC, 2006/95/EC

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC, 2004/108/EC

Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC

Noise level of Welding Generators: 2000/14/EC

CE Marking Directive: 93/68/EEC

Standards

Arc Welding Equipment Part 1: Welding Power Sources. IEC 60974-1 Ed. 3, 2005-07

Rotating Electrical Machines Part 1: Rating and Performance.IEC 60034-1 Ed. 11, 2004-04

Rotating Electrical Machines Part 5: Classification Of Degrees Of Protection Provided By Enclosure Of RotatingElectrical Machines (IP Code) IEC 60034-5 2001-06

Arc Welding Equipment Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10, Ed. 1.12004-10

The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.

dec_rotsound_6/05

Declaration of Conformity forEuropean Community (CE) Products

This information is provided for units with CE certification (see rating label on unit).

Manufacturer: European Contact: Notified Body:Miller Electric Mg. Co. Mr. Danilo Fedolfi, AV Technology Limited1635 W. Spencer St. Managing Director AVTECH HouseAppleton, WI 54914 USA ITW Welding Products Italy S.r.l. Birdhall LanePhone: (920) 734-9821 Via Privata Iseo 6/E Cheadle Heath

20098 San Giuliano Stockport, Chesire SK30XUMilanese, ItalyPhone: 39(02)98290-1Fax: 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.

OM-4435 Page 1

SECTION 1 SAFETY PRECAUTIONS READ BEFORE USINGrom_200704

Protect yourself and others from injury read and follow these precautions.

1-1. Symbol Usage

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. Arc Welding 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. The safety information given below isonly a summary of the more complete safety informationfound in the Safety Standards listed in Section 1-7. Read andfollow all Safety Standards.

Only qualified persons should install, operate, maintain, andrepair this unit.

During operation, keep everybody, especially children, away.

Touching live electrical parts can cause fatal shocks orsevere burns. The electrode and work circuit iselectrically live whenever the output is on. The input

power circuit and machine internal circuits are also live when power ison. In semiautomatic or automatic wire welding, the wire, wire reel,drive roll housing, and all metal parts touching the welding wire areelectrically live. Incorrectly installed or improperly grounded equip-ment is a hazard.

ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with the workor ground.

Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

Use AC output ONLY if required for the welding process.

If AC output is required, use remote output control if present onunit.

Additional safety precautions are required when any of the follow-ing electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoid-able or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic DC constant voltage (wire) welder, 2) a DC manual(stick) welder, or 3) an AC welder with reduced open-circuit volt-age. In most situations, use of a DC, constant voltage wire welderis recommended. And, do not work alone!

Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

When making input connections, attach proper grounding conduc-tor first double-check connections.

Keep cords dry, free of oil and grease, and protected from hot metaland sparks.

Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly

with a separate cable. Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine. Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual. Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will bepresent.

Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

Insulate work clamp when not connected to workpiece to preventcontact with any metal object.

Do not connect more than one electrode or work cable to anysingle weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverters after stop-ping engine. Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed. Allow cooling period before working on equip-

ment.

To handle hot parts, use proper tools and/or wear heavy, insu-lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.

Wear approved safety glasses with side shields even under yourwelding helmet.

OM-4435 Page 2

Welding produces fumes and gases. Breathing thesefumes and gases can be hazardous to your health.

FUMES AND GASES can be hazardous.

Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturers instructions for metals, consumables,coatings, cleaners, and degreasers.

Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.

BUILDUP OF GAS can injure or kill.

Shut off shielding gas supply when not in use. Always ventilate confined spaces or use ap-

proved air-supplied respirator.

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) rays thatcan burn eyes and skin. Sparks fly off from the weld.

ARC RAYS can burn eyes and skin.

Wear an approved welding helmet fitted with a proper shade of filterlenses to protect your face and eyes from arc rays and sparkswhen welding or watching (see ANSI Z49.1 and Z87.1 listed inSafety Standards).

Wear approved safety glasses with side shields under yourhelmet.

Use protective screens or barriers to protect others from flash,glare, and sparks; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant mate-rial (leather, heavy cotton, or wool) and foot protection.

Welding on closed containers, such as tanks, drums,or pipes, can cause them to blow up. Sparks can fly offfrom the welding arc. The flying sparks, hot workpiece,

and hot equipment can cause fires and burns. Accidental contact ofelectrode to metal objects can cause sparks, explosion, overheating,or fire. Check and be sure the area is safe before doing any welding.

WELDING can cause fire or explosion.

Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.

Do not weld where flying sparks can strike flammable material.

Protect yourself and others from flying sparks and hot metal.

Be alert that welding sparks and hot materials from welding caneasily go through small cracks and openings to adjacent areas.

Watch for fire, and keep a fire extinguisher nearby.

Be aware that welding on a ceiling, floor, bulkhead, or partition cancause fire on the hidden side.

Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

Do not weld where the atmosphere may contain flammable dust,gas, or liquid vapors (such as gasoline).

Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock, sparks, and fire haz-ards.

Do not use welder to thaw frozen pipes.

Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.

Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.

Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

After completion of work, inspect area to ensure it is free of sparks,glowing embers, and flames.

Use only correct fuses or circuit breakers. Do not oversize or by-pass them.

Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51Bfor hot work and have a fire watcher and extinguisher nearby.

NOISE can damage hearing.

Noise from some processes or equipment can dam-age hearing.

Wear approved ear protection if noise level ishigh.

MAGNETIC FIELDS can affect ImplantedMedical Devices.

Wearers of Pacemakers and other ImplantedMedical Devices should keep away.

Implanted Medical Device wearers should consult their doctorand the device manufacturer before going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heatingoperations.

Shielding gas cylinders contain gas under high pres-sure. If damaged, a cylinder can explode. Since gascylinders are normally part of the welding process, besure to treat them carefully.

CYLINDERS can explode if damaged.

Protect compressed gas cylinders from excessive heat, mechani-cal shocks, physical damage, slag, open flames, sparks, and arcs.

Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder explosion will result.

Use only correct shielding gas cylinders, regulators, hoses, and fit-tings designed for the specific application; maintain them andassociated parts in good condition.

Turn face away from valve outlet when opening cylinder valve.

Keep protective cap in place over valve except when cylinder is inuse or connected for use.

Use the right equipment, correct procedures, and sufficient num-ber of persons to lift and move cylinders.

Read and follow instructions on compressed gas cylinders,associated equipment, and Compressed Gas Association (CGA)publication P-1 listed in Safety Standards.

OM-4435 Page 3

1-3. Engine Hazards

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 or servicing battery.

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.

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 allow room for fuel to expand.

Do not spill fuel. If fuel is spilled, clean up before starting engine.

Dispose of rags in a fireproof container.

Always keep nozzle in contact with tank when fueling.

MOVING PARTS can cause injury.

Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guards

closed and securely in place.

Stop engine before installing or connecting unit.

Have only qualified people remove doors, panels, covers, orguards for maintenance and troubleshooting as necessary.

To prevent accidental starting during servicing, disconnectnegative () battery cable from battery.

Keep hands, hair, loose clothing, and tools away from movingparts.

Reinstall doors, panels, covers, or guards when servicing isfinished and before starting engine.

Before working on generator, remove spark plugs or injectors tokeep engine from kicking back or starting.

Block flywheel so that it will not turn while working on generatorcomponents.

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed. Allow cooling period before working on equip-

ment. To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves andclothing to prevent burns.

STEAM AND HOT COOLANT can burn.

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

Always check coolant level at overflow tank, ifpresent on unit, instead of radiator (unless toldotherwise in maintenance section or enginemanual).

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.

Using a generator indoors CAN KILLYOU 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.

BATTERY ACID can BURN SKIN and EYES.

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

ENGINE HEAT can cause fire.

Do not locate unit on, over, or near combustiblesurfaces or flammables.

Keep exhaust and exhaust pipes way fromflammables.

EXHAUST SPARKS can cause fire.

Do not let engine exhaust sparks cause fire. Use approved engine exhaust spark arrestor in

required areas see applicable codes.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR cancause serious injury or death.

Do not use compressed air for breathing. Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

Wear approved safety goggles. Do not direct air stream toward self or others.

TRAPPED AIR PRESSURE AND WHIPPINGHOSES can cause injury.

Release air pressure from tools and system be-fore servicing, adding or changing attach-ments, or opening compressor oil drain or oil fillcap.

OM-4435 Page 4

HOT METAL from air arc cutting andgouging can cause fire or explosion.

Do not cut or gouge near flammables. Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury.

Do not touch hot compressor or air systemparts.

Let system cool down before touching or ser-vicing.

READ INSTRUCTIONS.

Read Owners Manual before using or servic-ing unit.

Stop engine and release air pressure beforeservicing.

Use only genuine replacement parts from themanufacturer.

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

FIRE OR EXPLOSION hazard.

Do not install or place unit on, over, or nearcombustible surfaces.

Do not install unit near flammables.

Do not overload building wiring be sure power supply system isproperly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

Use lifting eye to lift unit and properly installedaccessories only, NOT gas cylinders. Do notexceed maximum lift eye weight rating (seeSpecifications).

Lift and support unit only with proper equipmentand correct procedures.

If using lift forks to move unit, be sure forks are long enough toextend beyond opposite side of unit.

OVERHEATING can damage motors.

Turn off or unplug equipment before starting orstopping engine.

Do not let low voltage and frequency caused bylow engine speed damage electric motors.

Do not connect 50 or 60 Hertz motors to the 100 Hertz receptaclewhere applicable.

FLYING SPARKS can cause injury.

Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with

proper guards in a safe location wearing properface, hand, and body protection.

Sparks can cause fires keep flammables away.

MOVING PARTS can cause injury.

Keep away from moving parts. Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

Do not press gun trigger until instructed to doso.

Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.

OVERUSE can cause OVERHEATING.

Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before

starting to weld again. Do not block or filter airflow to unit.

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.

TILTING OF TRAILER can cause injury.

Use tongue jack or blocks to support weight. Properly install welding generator onto trailer

according to instructions supplied with trailer.

READ INSTRUCTIONS.

Read Owners Manual before using or servic-ing unit.

Use only genuine replacement parts from themanufacturer.

Perform engine and air compressor mainte-nance and service according to this manualand the engine/air compressor (if applicable)manuals.

OM-4435 Page 5

H.F. RADIATION can cause interference.

High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

Have only qualified persons familiar withelectronic equipment perform this installation.

The user is responsible for having a qualified electricianpromptly correct any interference problem resulting from theinstallation.

If notified by the FCC about interference, stop using theequipment 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.

ARC WELDING can cause interference.

Electromagnetic energy can interfere withsensitive electronic equipment such as micro-processors, computers, and computer-drivenequipment such as robots.

Be sure all equipment in the welding area iselectromagnetically compatible.

To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive elec-tronic equipment.

Be sure this welding machine is installed and groundedaccording to this manual.

If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.

1-6. 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.

1-7. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, American Welding Society StandardAWS F4.1, from Global Engineering Documents (phone:1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:617-770-3000, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 4221 Walney Road, 5th Floor,Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 5060 Mississauga,

Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto416-747-4044, website: www.csa-international.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion, ANSI Standard Z87.1, from American National Standards Institute,25 West 43rd Street, New York, NY 100368002 (phone:212-642-4900, website: www.ansi.org).Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, from National Fire Protection Association,P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-site: www.nfpa.org.OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, from U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954(phone: 1-866-512-1800) (there are 10 Regional Officesphone forRegion 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-8. 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.

OM-4435 Page 6

SECTION 2 CONSIGNES DE SCURIT LIRE AVANTUTILISATION

rom_200704fre

Se protger, ainsi que toute autre personne travaillant sur les lieux, contre les tincelles et le mtal chaud.

2-1. Signification des symboles

DANGER! Indique une situation dangereuse qui si onlvite pas peut donner la mort ou des blessures graves.Les dangers possibles sont montrs par les symbolesjoints ou sont expliqus dans le texte.

Indique une situation dangereuse qui si on lvite paspeut donner la mort ou des blessures graves. Les dan-gers possibles sont montrs par les symboles joints ousont expliqus dans le texte.

NOTE Indique des dclarations pas en relation avec des blessurespersonnelles.

Indique des instructions spcifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGERDE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECESCHAUDES. Consulter les symboles et les instructions ci-dessous yaffrant pour les actions ncessaires afin dviter le danger.

2-2. Dangers relatifs au soudage larc

Les symboles prsents ci-aprs sont utiliss tout au long duprsent manuel pour attirer votre attention et identifier les ris-ques de danger. Lorsque vous voyez un symbole, soyezvigilant et suivez les directives mentionnes afin dviter toutdanger. Les consignes de scurit prsentes ci-aprs nefont que rsumer linformation contenue dans les normes descurit numres la section 2-7. Veuillez lire et respectertoutes ces normes de scurit.

Linstallation, lutilisation, lentretien et les rparations nedoivent tre confis qu des personnes qualifies.

Au cours de lutilisation, tenir toute personne lcart et plusparticulirement les enfants.

Un simple contact avec des pices lectriques peutprovoquer une lectrocution ou des blessures graves.Llectrode et le circuit de soudage sont sous tension

ds que lappareil est sur ON. Le circuit dentre et les circuitsinternes de lappareil sont galement sous tension ce moment-l.En soudage semi-automatique ou automatique, le fil, le dvidoir, lelogement des galets dentranement et les pices mtalliques encontact avec le fil de soudage sont sous tension. Des matriels malinstalls ou mal mis la terre prsentent un danger.

UN CHOC LECTRIQUE peut tuer.

Ne jamais toucher les pices lectriques sous tension.

Porter des gants et des vtements de protection secs ne compor-tant pas de trous.

Sisoler de la pice et de la terre au moyen de tapis ou dautresmoyens isolants suffisamment grands pour empcher le contactphysique ventuel avec la pice ou la terre.

Ne pas se servir de source lectrique courant lectrique dans leszones humides, dans les endroits confins ou l o on risque detomber.

Se servir dune source lectrique courant lectrique UNIQUE-MENT si le procd de soudage le demande.

Si lutilisation dune source lectrique courant lectrique savrencessaire, se servir de la fonction de tlcommande si lappareilen est quip.

Des prcautions de scurit supplmentaires sont requises dansdes environnements risque comme: les endroits humides oulorsque lon porte des vtements mouills; sur des structures m-talliques au sol, grillages et chafaudages; dans des positionsassises, genoux et allonges; ou quand il y a un risque importantde contact accidentel avec la pice ou le sol. Dans ces cas utiliserles appareils suivants dans lordre de prfrence: 1) un poste souder DC semiautomatique de type CV (MIG/MAG), 2) un poste souder manuel (lectrode enrobe) DC, 3) un poste souder

manuel AC avec tension vide rduite. Dans la plupart des cas, unposte courant continu de type CV est recommand. Et, ne pas tra-vailler seul!

Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil.Dverrouiller lalimentation selon la norme OSHA 29 CFR1910.147 (voir normes de scurit).

Installer et mettre la terre correctement cet appareil conform-ment son manuel dutilisation et aux codes nationaux,provinciaux et municipaux.

Toujours vrifier la terre du cordon dalimentation Vrifier etsassurer que le fil de terre du cordon dalimentation est bienraccord la borne de terre du sectionneur ou que la fiche ducordon est raccorde une prise correctement mise la terre.

En effectuant les raccordements dentre fixer dabord le conduc-teur de mise la terre appropri et contre-vrifier les connexions.

Les cbles doivent tre exempts dhumidit, dhuile et de graisse;protgezles contre les tincelles et les pices mtalliques chau-des.

Vrifier frquemment le cordon dalimentation pour voir sil nestpas endommag ou dnud remplacer le cordon immdiatementsil est endommag un cble dnud peut provoquer une lectro-cution.

Mettre lappareil hors tension quand on ne lutilise pas. Ne pas utiliser des cbles uss, endommags, de grosseur insuffi-

sante ou mal pisss. Ne pas enrouler les cbles autour du corps. Si la pice soude doit tre mise la terre, le faire directement

avec un cble distinct ne pas utiliser le connecteur de pice ou lecble de retour.

Ne pas toucher llectrode quand on est en contact avec la pice,la terre ou une lectrode provenant dune autre machine.

Ne pas toucher des porte lectrodes connects deux machinesen mme temps cause de la prsence dune tension vide dou-ble.

Nutiliser quun matriel en bon tat. Rparer ou remplacersur-le-champ les pices endommages. Entretenir lappareilconformment ce manuel.

Porter un harnais de scurit quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le cble de retour de faon obtenir un bon contact mtal-

mtal avec la pice souder ou la table de travail, le plus prspossible de la soudure.

Isoler la pince de masse quand pas mis la pice pour viter lecontact avec tout objet mtallique.

Une tension DC importante subsiste lintrieurdes onduleurs aprs avoir coup lalimentation. Couper lalimentation du poste et dcharger les condensateurs

dentre comme indiqu dans la Section Maintenance avant detoucher des composants.

OM-4435 Page 7

DES PICES CHAUDES peuventprovoquer des brlures graves.

Ne pas toucher mains nues les parties chau-des.

Prvoir une priode de refroidissement avantde travailler lquipement.

Ne pas toucher aux pices chaudes, utiliser les outils recomman-ds et porter des gants de soudage et des vtements pais pourviter les brlures.

DES PIECES DE METAL ou DESSALETES peuvent provoquerdes blessures dans les yeux.

Le soudage, lcaillement, le passage de la pice la brosse enfil de fer, et le meulage gnrent des tincelles et des particulesmtalliques volantes. Pendant la priode de refroidissement dessoudures, elles risquent de projeter du laitier.

Porter des lunettes de scurit avec crans latraux ou un cranfacial.

Le soudage gnre des fumes et des gaz. Leurinhalation peut tre dangereux pour votre sant.

LES FUMES ET LES GAZ peu-vent tre dangereux.

Eloigner votre tte des fumes. Ne pas respirer les fumes.

lintrieur, ventiler la zone et/ou utiliser une ventilation force auniveau de larc pour lvacuation des fumes et des gaz de soudage.

Si la ventilation est mdiocre, porter un respirateur anti-vapeursapprouv.

Lire et comprendre les spcifications de scurit des matriaux(MSDS) et les instructions du fabricant concernant les mtaux, lesconsommables, les revtements, les nettoyants et les dgraisseurs.

Travailler dans un espace ferm seulement sil est bien ventil ouen portant un respirateur alimentation dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes etdes gaz de soudage peuvent dplacer lair et abaisser le niveaudoxygne provoquant des blessures ou des accidents mortels.Sassurer que lair de respiration ne prsente aucun danger.

Ne pas souder dans des endroits situs proximit doprationsde dgraissage, de nettoyage ou de pulvrisation. La chaleur etles rayons de larc peuvent ragir en prsence de vapeurs et for-mer des gaz hautement toxiques et irritants.

Ne pas souder des mtaux munis dun revtement, tels que laciergalvanis, plaqu en plomb ou au cadmium moins que le revte-ment nait t enlev dans la zone de soudure, que lendroit soitbien ventil, et en portant un respirateur alimentation dair. Lesrevtements et tous les mtaux renfermant ces lments peuventdgager des fumes toxiques en cas de soudage.

LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumme la mort.

Fermer lalimentation du gaz protecteur en casde non utilisation.

Veiller toujours bien arer les espaces confins ou se servirdun respirateur dadduction dair homologu.

LES RAYONS DE LARC peuventprovoquer des brlures dans lesyeux et sur la peau.Le rayonnement de larc du procd de soudagegnre des rayons visibles et invisibles intenses

(ultraviolets et infrarouges) susceptibles de provoquer des brluresdans les yeux et sur la peau. Des tincelles sont projetes pendant lesoudage.

Porter un casque de soudage approuv muni de verres filtrantsappropri pour protger visage et yeux pendant le soudage(voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit).

Porter des lunettes de scurit avec crans latraux mme sousvotre casque.

Avoir recours des crans protecteurs ou des rideaux pourprotger les autres contre les rayonnements les blouissementset les tincelles ; prvenir toute personne sur les lieux de ne pasregarder larc.

Porter des vtements confectionns avec des matires rsistan-tes et ignifuges (cuir, coton lourd ou laine) et des bottes deprotection.

Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuvent

tre projetes de larc de soudure. La projection dtincelles, despices chaudes et des quipements chauds peut provoquer desincendies et des brlures. Le contact accidentel de llectrode avecdes objets mtalliques peut provoquer des tincelles, une explosion,un surchauffement ou un incendie. Avant de commencer le soudage,vrifier et sassurer que lendroit ne prsente pas de danger.

LE SOUDAGE peut provoquer unincendie ou une explosion.

Dplacer toutes les substances inflammables une distance de10,7 m de larc de soudage. En cas dimpossibilit les recouvrirsoigneusement avec des protections homologus.

Ne pas souder dans un endroit l o des tincelles peuvent tombersur des substances inflammables.

Se protger et dautres personnes de la projection dtincelles etde mtal chaud.

Des tincelles et des matriaux chauds du soudage peuventfacilement passer dans dautres zones en traversant de petitesfissures et des ouvertures.

Surveiller tout dclenchement dincendie et tenir un extincteur proximit.

Le soudage effectu sur un plafond, plancher, paroi ou sparationpeut dclencher un incendie de lautre ct.

Ne pas effectuer le soudage sur des conteneurs ferms tels quedes rservoirs, tambours, ou conduites, moins quils naient tprpars correctement conformment AWS F4.1 (voir les nor-mes de scurit).

Ne soudez pas si lair ambiant est charg de particules, gaz, ou va-peurs inflammables (vapeur dessence, par exemple).

Brancher le cble de masse sur la pice le plus prs possible de lazone de soudage pour viter le transport du courant sur unelongue distance par des chemins inconnus ventuels en provo-quant des risques dlectrocution, dtincelles et dincendie.

Ne pas utiliser le poste de soudage pour dgeler des conduites ge-les.

En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.

Porter des vtements de protection dpourvus dhuile tels que desgants en cuir, une chemise en matriau lourd, des pantalons sansrevers, des chaussures hautes et un couvre chef.

Avant de souder, retirer toute substance combustible de vos po-ches telles quun allumeur au butane ou des allumettes.

Une fois le travail achev, assurezvous quil ne reste aucune tra-ce dtincelles incandescentes ni de flammes.

Utiliser exclusivement des fusibles ou coupecircuits appropris.Ne pas augmenter leur puissance; ne pas les ponter.

Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) etNFPA 51B pour les travaux chaud et avoir de la surveillance et unextincteur proximit.

LE BRUIT peut affecter loue.

Le bruit des processus et des quipements peutaffecter loue.

Porter des protections approuvs pour lesoreilles si le niveau sonore est trop lev.

OM-4435 Page 8

LES CHAMPS MAGNETIQUES peuventaffecter des implants mdicaux.

Porteur de simulateur cardiaque ou autre im-plants mdicaux, rester distance.

Les porteurs dimplants doivent dabord consulter leur mdecinavant de sapprocher des oprations de soudage larc, de sou-dage par points, de gougeage, du coupage plasma ou de chauf-fage par induction.

Si des BOUTEILLES sont endomma-ges, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endomma-

ge, elle peut exploser. Du fait que les bouteilles de gaz fontnormalement partie du procd de soudage, les manipuler avecprcaution.

Protger les bouteilles de gaz comprim dune chaleur excessive,des chocs mcaniques, des dommages physiques, du laitier, desflammes ouvertes, des tincelles et des arcs.

Placer les bouteilles debout en les fixant dans un support station-naire ou dans un porte-bouteilles pour les empcher de tomber oude se renverser.

Tenir les bouteilles loignes des circuits de soudage ou autrescircuits lectriques.

Ne jamais placer une torche de soudage sur une bouteille gaz.

Une lectrode de soudage ne doit jamais entrer en contact avecune bouteille.

Ne jamais souder une bouteille pressurise risque dexplosion.

Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,tuyaux et raccords convenables pour cette application spcifique;les maintenir ainsi que les lments associs en bon tat.

Ne pas tenir la tte en face de la sortie en ouvrant la soupape de labouteille.

Maintenir le chapeau de protection sur la soupape, sauf en casdutilisation ou de branchement de la bouteille.

Utiliser les quipements corrects, les bonnes procdures et suffi-samment de personnes pour soulever et dplacer les bouteilles.

Lire et suivre les instructions sur les bouteilles de gaz comprim,lquipement connexe et le dpliant P-1 de la CGA (Compressed GasAssociation) mentionn dans les principales normes de scurit.

2-3. Dangers existant en relation avec le moteur

LEXPLOSION DE LA BATTERIEpeut RENDRE AVEUGLE.

Toujours porter une protection faciale, des gantsen caoutchouc et vtements de protection lorsdune intervention sur la batterie.

Arrter le moteur avant de dbrancher ou de brancher les cblesde batterie.

Eviter de provoquer des tincelles avec les outils en travaillant surla batterie.

Ne pas utiliser le poste de soudage pour charger les batteries oudes vhicules de dmarrage rapide.

Observer la polarit correcte (+ et ) sur les batteries.

Dbrancher le cble ngatif () en premier lieu. Le rebrancher endernier lieu.

LE CARBURANT MOTEUR peut pro-voquer un incendie ou une explosion.

Arrter le moteur avant de vrifier le niveau decarburant ou de faire le plein.

Ne pas faire le plein en fumant ou proche dune source dtincel-les ou dune flamme nue.

Ne pas faire le plein de carburant ras bord; prvoir de lespacepour son expansion.

Faire attention de ne pas renverser de carburant. Nettoyer toutcarburant renvers avant de faire dmarrer le moteur.

Jeter les chiffons dans un rcipient ignifuge.

Toujours garder le pistolet en contact avec le rservoir lors du remplissage.

DES ORGANES MOBILES peuventprovoquer des blessures.

Ne pas approcher les mains des ventilateurs,courroies et autres pices en mouvement.

Maintenir ferms et fixement en place les portes, panneaux, re-couvrements et dispositifs de protection.

Arrter le moteur avant dinstaller ou brancher lappareil.

Seules des personnes qualifies sont autorises enlever les por-tes, panneaux, recouvrements ou dispositifs de protection poureffectuer, sil y a lieu, des travaux dentretien et de dpannage.

Pour empcher tout dmarrage accidentel pendant les travauxdentretien, dbrancher le cble ngatif () de batterie de la borne.

Ne pas approcher les mains, cheveux, vtements lches et outilsdes organes mobiles.

Remettre en place les panneaux ou les dispositifs de protection etfermer les portes la fin des travaux dentretien et avant de fairedmarrer le moteur.

Avant dintervenir, dposer les bougies ou injecteurs pour viter lamise en route accidentelle du moteur.

Bloquer le volant moteur pour viter sa rotation lors dune interven-tion sur le gnrateur.

DES PICES CHAUDES peuventprovoquer des brlures graves.

Ne pas toucher mains nues les parties chau-des.

Prvoir une priode de refroidissement avant detravailler lquipement.

Ne pas toucher aux pices chaudes, utiliser les outils recomman-ds et porter des gants de soudage et des vtements pais pourviter les brlures.

LA VAPEUR ET LE LIQUIDE DEREFROIDISSEMENT CHAUD peuventprovoquer des brlures.

Il est prfrable de vrifier le liquide de refroi-dissement une fois le moteur refroidi pour viterde se brler.

Toujours vrifier le niveau de liquide de refroidissement dans levase dexpansion (si prsent), et non dans le radiateur (sauf si pr-cis autrement dans la section maintenance du manuel dumoteur).

Si le moteur est chaud et que le liquide doit tre vrifi, oprer com-me suivant.

Mettre des lunettes de scurit et des gants, placer un torchon surle bouchon du radiateur.

Dvisser le bouchon lgrement et laisser la vapeur schapperavant denlever le bouchon.

OM-4435 Page 9

Lutilisation dun groupe autonome lintrieur PEUT VOUS TUER ENQUELQUES MINUTES.

Les fumes dun groupe autonome contient dumonoxyde de carbone. Cest un poison invisi-ble et inodore.

JAMAIS utiliser dans une maison ou garage,mme avec les portes et fentres ouvertes.

Uniquement utiliser lEXTERIEUR, loin des portes, fentres etbouches aration.

LACIDE DE LA BATTERIE peut pro-voquer des brlures dans les YEUX etsur la PEAU.

Ne pas renverser la batterie. Remplacer une batterie endommage.

Rincer immdiatement les yeux et la peau leau.

LA CHALEUR DU MOTEUR peut pro-voquer un incendie.

Ne pas placer lappareil sur, au-dessus ou proximit de surfaces inflammables.

Tenir distance les produits inflammables de lchappement.

LES TINCELLES LCHAPPEMENTpeuvent provoquer un incendie.

Empcher les tincelles dchappement dumoteur de provoquer un incendie.

Utiliser uniquement un pare-tincellesapprouv voir codes en vigueur.

2-4. Dangers lis lair comprim

RESPIRER LAIR COMPRIM peut pro-voquer des blessures graves ou causerla mort.

Ne pas utiliser lair comprim pour respirer. Utiliser lair comprim seulement pour le cou-

page, gougeage et les outils pneumatiques.

LAIR COMPRIM peut provoquerdes blessures.

Porter des lunettes de scurit approuves. Ne pas diriger le jet dair vers dautres ou

soi-mme.

LAIR COMPRIME EMMAGASINE ET DESTUYAUX SOUS PRESSION peuvent provo-quer des blessures.

Relcher la pression dair de loutillage ou dusystme avant deffectuer la maintenance,avant de changer ou de rajouter des lmentsou avant douvrir la purge ou le bouchon deremplissage dhuile.

Le METAL CHAUD lors du coupage etgougeage plasma peut provoquer un in-cendie ou une explosion.

Ne pas couper ou gouger proximit de pro-duits inflammables.

Surveillez et garder un extincteur proximit.

DES PIECES CHAUDES peuvent provo-quer des brlures et blessures.

Ne pas toucher le compresseur ou dautreslments du circuit air comprim chauds.

Laisser lensemble se refroidir avant de toucher ou deffectuer lamaintenance.

LIRE LES INSTRUCTIONS.

Lisez le manuel dinstructions avant lutilisationou la maintenance de lappareil.

Arrter le moteur et relcher la pression avantdeffectuer la maintenance.

Nutiliser que les pices de rechange recommandes par leconstructeur.

2-5. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OU DEXPLO-SION. Ne pas placer lappareil sur, au-dessus ou

proximit de surfaces inflammables. Ne pas installer lappareil proximit de pro-

duits inflammables.

Ne pas surcharger linstallation lectrique sassurer que lali-mentation est correctement dimensionne et protge avant demettre lappareil en service.

LA CHUTE DE LAPPAREIL peut blesser.

Utiliser lanneau de levage pour lever lappareilet les accessoires correctement installesseuls, PAS les bouteilles de gaz. Ne pas d-passer le poids nominal maximal de lilleton(voir les spcifications).

Ne lever et ne soutenir lappareil quavec delquipement appropri et en suivant lesprocdures adquates.

En utilisant des fourches de levage pour dplacer lunit, sassu-rer que les fourches sont suffisamment longues pour dpasserdu ct oppos de lappareil.

OM-4435 Page 10

LE SURCHAUFFEMENT peut endom-mager le moteur lectrique.

Arrter ou dconnecter lquipement avant dedmarrer ou darrter le moteur.

Ne pas laisser tourner le moteur trop lentement sous risque den-dommager le moteur lectrique cause dune tension et dune fr-quence trop faibles.

Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz,sil y a lieu.

LES TINCELLES VOLANTES ris-quent de provoquer des blessures.

Porter un cran facial pour protger le visage etles yeux.

Affter llectrode au tungstne uniquement la meuleuse dote de protecteurs. Cette ma-nuvre est excuter dans un endroit sr lors-que lon porte lquipement homologu de pro-tection du visage, des mains et du corps.

Les tincelles risquent de causer un incendie loigner toutesubstance inflammable.

DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas sapprocher des organes mobiles. Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuventprovoquer des blessures. Ne pas appuyer sur la gchette avant den

avoir reu linstruction. Ne pas diriger le pistolet vers soi, dautres per-

sonnes ou toute pice mcanique en enga-geant le fil de soudage.

LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT.

Laisser lquipement refroidir ; respecter le fac-teur de marche nominal.

Rduire le courant ou le facteur de marcheavant de poursuivre le soudage.

Ne pas obstruer les passages dair du poste.

LES CHARGES LECTROSTATI-QUES peuvent endommager lescircuits imprims.

tablir la connexion avec la barrette de terreavant de manipuler des cartes ou des pices.

Utiliser des pochettes et des botes antistatiques pour stocker,dplacer ou expdier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peutentraner des blessures. Utiliser les supports de la remorque ou des

blocs pour soutenir le poids. Installer convenablement le poste sur la remor-

que comme indiqu dans le manuel sy rappor-tant.

LIRE LES INSTRUCTIONS.

Lisez le manuel dinstructions avant lutilisationou la maintenance de lappareil.

Nutiliser que les pices de rechange recom-mandes par le constructeur.

Effectuer la maintenance et le service du moteur et du compres-seur dair suivant les instructions dans ce manuel ou le manueldu moteur/compresseur (si applicable).

LE RAYONNEMENT HAUTE FR-QUENCE (H.F.) risque de provoquerdes interfrences.

Le rayonnement haute frquence (H.F.) peutprovoquer des interfrences avec les quipe-ments de radionavigation et de communica-tion, les services de scurit et les ordinateurs.

Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstal-lation.

Lutilisateur est tenu de faire corriger rapidement par un lectri-cien qualifi les interfrences rsultant de linstallation.

Si le FCC signale des interfrences, arrter immdiatement lap-pareil.

Effectuer rgulirement le contrle et lentretien de linstallation.

Maintenir soigneusement ferms les portes et les panneaux dessources de haute frquence, maintenir les clateurs une dis-tance correcte et utiliser une terre et un blindage pour rduire lesinterfrences ventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences.

Lnergie lectromagntique risque de provo-quer des interfrences pour lquipement lec-tronique sensible tel que les ordinateurs etlquipement command par ordinateur tel queles robots.

Veiller ce que tout lquipement de la zone de soudage soitcompatible lectromagntiquement.

Pour rduire la possibilit dinterfrence, maintenir les cbles desoudage aussi courts que possible, les grouper, et les poseraussi bas que possible (ex. par terre).

Veiller souder une distance de 100 mtres de tout quipe-ment lectronique sensible.

Veiller ce que ce poste de soudage soit pos et mis la terreconformment ce mode demploi.

En cas dinterfrences aprs avoir pris les mesures prcden-tes, il incombe lutilisateur de prendre des mesures suppl-mentaires telles que le dplacement du poste, lutilisation de c-bles blinds, lutilisation de filtres de ligne ou la pose de protec-teurs dans la zone de travail.

OM-4435 Page 11

2-6. Proposition californienne 65 Avertissements

Les quipements de soudage et de coupage produisent desfumes et des gaz qui contiennent des produits chimiquesdont ltat de Californie reconnat quils provoquent des mal-formations congnitales et, dans certains cas, des cancers.(Code de sant et de scurit de Californie, chapitre 25249.5et suivants)

Les batteries, les bornes et autres accessoires contiennentdu plomb et des composs base de plomb, produits chimi-ques dont ltat de Californie reconnat quils provoquent descancers et des malformations congnitales ou autresproblmes de procration. Se laver les mains aprs manipu-lation.

Pour les moteurs essence :

Les gaz dchappement des moteurs contiennent des pro-duits chimiques dont ltat de Californie reconnat quilsprovoquent des cancers et des malformations congnitalesou autres problmes de procration.

Pour les moteurs diesel :

Les gaz dchappement des moteurs diesel et certains deleurs composants sont reconnus par ltat de Californie com-me provoquant des cancers et des malformationscongnitales ou autres problmes de procration.

2-7. Principales normes de scuritSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents (tlphone : 1-877-413-5184, siteInternet : www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, American Welding Society StandardAWS F4.1 de Global Engineering Documents (tlphone :1-877-413-5184, site Internet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protec-tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (tlphone :617-770-3000, site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-tilly, VA 20151 (tlphone : 703-788-2700, site Internet :www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, deCanadian Standards Association, 5060 Mississauga, Ontario, Canada

L4W 5NS (tlphone : 800-463-6727 ou Toronto 416-747-4044, siteInternet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-tion, ANSI Standard Z87.1, de American National Standards Institute,11 West 43rd Street, New York, NY 10036-8002 (tlphone :212-642-4900, site Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, de National Fire Protection Association,P.O. Box 9101, Quincy, MA 02269-9101 (tlphone : 617-770-3000,site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954(tlphone : 1-866-512-1800) (il y a 10 bureaux rgionauxle tlpho-ne de la rgion 5, Chicago, est 312-353-2220, site Internet :www.osha.gov).

2-8. Information EMFConsidrations sur le soudage et les effets de basse frquence et deschamps magntiques et lectriques.Le courant de soudage, pendant son passage dans les cbles de sou-dage, causera des champs lectromagntiques. Il y a eu et il y a encoreun certain souci propos de tels champs. Cependant, aprs avoir exa-min plus de 500 tudes qui ont t faites pendant une priode derecherche de 17 ans, un comit spcial ruban bleu du NationalResearch Council a conclu : Laccumulation de preuves, suivant lejugement du comit, na pas dmontr que lexposition aux champsmagntiques et champs lectriques haute frquence reprsente unrisque la sant humaine . Toutefois, des tudes sont toujours encours et les preuves continuent tre examines. En attendant que lesconclusions finales de la recherche soient tablies, il vous seraitsouhaitable de rduire votre exposition aux champs lectromagnti-ques pendant le soudage ou le coupage.Pour rduire les champs magntiques sur le poste de travail, appliquerles procdures suivantes :

1. Garder les cbles ensemble, les torsader, les scotcher, ou lesrecouvrir dune housse.

2. Disposer les cbles dun ct et distance de loprateur.3. Ne pas courber pas et ne pas entourer pas les cbles autour de

votre corps.4. Garder le poste de soudage et les cbles le plus loin possible de

vous.5. Connecter la pince sur la pice aussi prs que possible de la

soudure.

En ce qui concerne les implants mdicaux :

Les porteurs dimplants doivent dabord consulter leur mdecin avantde sapprocher des oprations de soudage larc, de soudage parpoints, de gougeage, du coupage plasma ou de chauffage par induc-tion. Si le mdecin approuve, il est recommand de suivre lesprocdures prcdentes.

OM-4435 Page 12

SECTION 3 DEFINITIONS

3-1. Warning Label Definitions

3/96

1 Remove unit from shippingcrate. Remove OwnersManual from unit. Followinstructions to install muffler.

2 Read Owners Manual. Readlabels on unit.

3 Use Diesel Fuel only, and fillfuel 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 ifnecessary.

6 During the first 50 hours ofoperation, keep welding loadabove 200 amperes. Do notweld below 200 amperes ofoutput.

7 After the first 50 hours ofoperation, 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 the

safety rules at

the beginning

of this manual.

OM-4435 Page 13

3-2. Symbols And Definitions Some symbols are found only on CE products.

Stop EngineFast (Run, Weld/

Power) Slow (Idle) Start Engine

Starting Aid(Preheat) Battery (Engine)

Engine OilPressure Engine Oil

Check Injectors/Pump

Check ValveClearance Fuel

Protective Earth(Ground)

Positive NegativeCertified/Trained

Mechanic Welding Arc

A Amperes V Volts Panel/Local RemoteEngine

Air Temperature OrEngine

TemperatureOutput

AlternatingCurrent

Stick (SMAW)Welding

Constant Current(CC)

MIG (GMAW)Welding

TIG (GTAW)Welding

Time h Hours s Seconds 1 Single Phase

3 Three Phase Read OperatorsManual Circuit Protection Do Not SwitchWhile Welding

ElectrodeConnection Work Connection 3

G

Engine-Driven,Three-Phase

Alternator WithRectifier

Hz Hertz

X Duty Cycle U0 Rated No LoadVoltage (Average) U2 ConventionalLoad Voltage nRated Load

Speed

n1 Rated IdleSpeed n0 Rated No LoadSpeed I Current I2 Rated WeldingCurrent

Contactor On Arc Force (Dig) Lift-Arc TIGRemote FootControl TIG

(GTAW)

OM-4435 Page 14

SECTION 4 SPECIFICATIONS4-1. Weld, Power, And Engine Specifications

WeldingMode

Weld OutputRange

Rated WeldingOutput

MaximumOpen-CircuitVoltage

Auxiliary Power Rating Engine FuelCapacity

CC/DC20 410 A 300 A, 32 Volts DC60% Duty Cycle

250 A, 30 Volts DC100% Duty cycle

73

GeneratorSingle-Phase,

10 kVA/kW, 91/46 A,110/220 V AC,

60 Hz Catepillar C1.5WaterCooledThreeCylinder

21.7 HP Diesel Engine

11.5 gal(43.5 L)

CV/DCFlux Core 14 40 V

300 A, 29 Volts DC60% Duty Cycle

250 A, 26.5 Volts DC100% Duty cycle

Receptacles110/55 V AC Receptacles

5.5 kVA/kW, 50/100 A

220/110 V AC Receptacles 11 kVA/kW, 50/20 A

4-2. Dimensions, Weights, And Operating Angles

Dimensions

Front Panel End

BA

FE

H

G

C

D

20

20

30

30

! Do not exceed tilt angles or engine couldbe damaged or unit could tip.

! Do not move or operate unit where it couldtip.

Height32 in (813 mm)

35-3/4 in (908 mm)(to top of lift eye)

Width

26-1/4 in (667 mm)(mtg. brackets turned in)

28-3/4 in (730 mm)(mtg. brackets turned out)

Depth 56 in (1422 mm)

A 56 in (1422 mm)

B 54 in (1372 mm)

C 52 in in (1321 mm)

D 2 in (51 mm)

E 26 in (660 mm)

F 7/8 in (22 mm)

G 27-3/4 in (705 mm)

H9/16 in (14 mm) Dia.

4 Holes

Weight

No fuel: 1128 lb (512 kg)

w/ fuel: 1210 lb (549 kg)

Lifting Eye Weight Rating:1500 lb (680 kg) Maximum

OM-4435 Page 15

4-3. Volt-Ampere Curves

237 466 / 237 468 / 237 470

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

A. Stick Mode

B. MIG Mode

C. TIG Mode

0 100 200 300 400 500 6000

10

20

30

40

50

60

70

80

90

100

DC

Vol

ts

DC Amperes

Min

Max

0 100 200 300 400 500 600DC Amperes

0

10

20

30

40

50

60

70

80

90

100

DC

Vol

ts

0 100 200 300 400 500DC Amperes

0

10

20

30

40

50

60

70

80

90

100

DC

Vol

ts

Min

Max

OM-4435 Page 16

4-4. Fuel Consumption

The curve shows typical fuel useunder weld or power loads.

237 471

DC WELD AMPERES AT 100% DUTY CYCLE

U.S

. GA

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

IDLE

4-5. Duty Cycle And Overheating

1 100% Duty Cycle

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

This unit is rated for welding at250 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

WE

LD A

MP

ER

ES

% DUTY CYCLE

1

OM-4435 Page 17

4-6. AC Generator Power Curve

220 346B

The AC power curve shows thegenerator power in amperes.

AC AMPERES IN 110V MODE

AC AMPERES IN 220V MODE

AC

VO

LTS

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

OM-4435 Page 18

SECTION 5 INSTALLATION

! Do not move or operate unitwhere it could tip.

! Always securely fasten weld-ing generator onto transportvehicle or trailer and complywith all DOT and other applica-ble codes.

NOTICE Do not install unit whereair flow is restricted or engine mayoverheat.

See Section 4-2 for lifting eye rat-ing.

See Section 5-2 for mountinginformation.

install3 2008-01 Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

18 in(460 mm)

18 in(460 mm)

18 in(460 mm)

18 in(460 mm)

18 in(460 mm)

Movement

5-1. Installing Welding Generator

OR OR

OR

Location/Airflow Clearance

OR

OM-4435 Page 19

5-2. 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 bysupporting the base only at the fourmounting brackets. Use cross-supports to adequately support unitand prevent damage to base.

Mounting Surface:

1 Cross-Supports

2 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 thefour 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

2

Supporting The Unit

Using Mounting Brackets

install3 2008--01 803 274 / 200 864-A / 803 231

1

OR

3

OM-4435 Page 20

! Always ground generatorframe to vehicle frame to pre-vent electric shock and staticelectricity hazards.

! Also see AWS Safety &Health Fact Sheet No. 29,Grounding of Portable AndVehicle Mounted WeldingGenerators.

! Bed liners, shipping skids,and some running gear insu-late the welding generatorfrom the vehicle frame. Al-ways connect a ground wirefrom the generator equip-ment grounding terminal tobare metal on the vehicleframe as shown.

! If unit does not have GFCI re-ceptacles, use GFCI-pro-tected extension cord.

1 Equipment GroundingTerminal (On Front Panel)

2 Grounding Cable (NotSupplied)

3 Metal Vehicle Frame

Connect cable from equipmentground terminal to metal vehicleframe. Use #10 AWG or largerinsulated copper wire.

Electrically bond generatorframe to vehicle frame by met-al-to-metal contact.

5-3. Grounding Generator To Truck Or Trailer Frame

rot_grnd 2008-01 800 652-D

1

3

2

GND/PE

1 Rating Label Typical

Locate rating label on unit. Label pro-vides information such as weld outputratings, generator ratings, and engineinformation.

Evidence of label tampering voidswarranty.

rot_label 2008-01 804 712

1

5-4. Rating Label Location

OM-4435 Page 21

5-5. Installing Exhaust Pipe

1/2 in

Tools Needed:

803 582 / Ref. 217 357-A

! Stop engine and let cool.

Point exhaust pipe in desired di-rection but always away from frontpanel and direction of travel.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4435 Page 22

5-6. Activating The Dry Charge Battery (If Applicable)

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

Remove battery from unit.

1 Vent Caps

2 Sulfuric Acid Electrolyte(1.265 Specific Gravity)

3 Well

Fill 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.

4 Battery Charger

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

5 5 Amperes For 30 MinutesCharge Time

6 30 Amperes For 12 MinutesCharge Time

Charge battery. Disconnect charg-ing cables and install battery.

When electrolyte is low, addonly distilled water to cells tomaintain proper level.

1

Tools Needed:

2

4

+

3

drybatt 1200801 S-0886

5

6

30 A

5 A

5-7. Connecting The Battery

1/2 in

+

Tools Needed:

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

! Connect negative () batterycable last.

Close door after connectingbattery.

OM-4435 Page 23

5-8. 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 ifoil 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 leveloften and do not use the oil pressureshutdown 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 10.FuelNOTICE 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.

Engine stops if fuel level is low.

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 6-1).

Keep battery in good condition. Storebattery 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 coolantlevel when fluid is low in

recovery tank.

Coolant Recovery Tank

Ref. 804 009C

Full

OM-4435 Page 24

5-9. 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 placeanything between

Correct Installation Incorrect Installation

3

weld cable terminaland copper bar.

! Stop engine.1 Work () Weld Output Terminal

2 Positive (+) Weld Output Terminal(s)

! Failure to properly connect weldcables may cause excessive heat andstart 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 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 Positive (+) terminal and workcable 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 6-3).

MIG and FCAW WeldingFor MIG and FCAW welding Direct CurrentElectrode Positive (DCEP), connect wirefeeder cable to Positive (+) terminal and workcable to Negative () terminal on left. Use Pro-cess switch to select type of weld output (seeSection 6-3).

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

12

OM-4435 Page 25

5-10. Selecting Weld Cable Sizes*

Weld OutputTerminals

! Stop engine beforeconnecting to weldoutput terminals.

! Do not use worn,damaged, under-sized, or poorlyspliced 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%DutyCycle

60 100%DutyCycle

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.( ) = 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

OM-4435 Page 26

5-11. Connecting To Remote 14 Receptacle RC14

OR

Ref 804 009-C

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. ofremote control with Voltage/Amperage Adjust control atmax.

FCurrent feedback: 1 volt per100 amperes.

H Voltage feedback: 1 volt per 10arc volts.

GND K Chassis common.

NEUTRAL G Circuit common for 24 volt ACcircuit.

*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.

OM-4435 Page 27

Notes

OM-4435 Page 28

SECTION 6 OPERATING WELDING GENERATOR

6-1. Front Panel Controls (See Section 6-2)

226 390A / 804 009C

1 2 546 7 89 10

3

Stop

OM-4435 Page 29

6-2. Description Of Front Panel Controls (See Section 6-1)

Engine Starting Controls

1 Preheat Switch

Use switch to energize starting aid for coldweather starting (see starting instructions fol-lowing).

2 Engine Control Switch

Use switch to start engine, select enginespeed (if unit has auto idle option