motosoldadoras miller
TRANSCRIPT
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Processes
TM-4435B 200605
Eff. w/Serial Number LE341957
Description
Engine Driven Welding Generator
Big Blue 400 CX
Air Carbon Arc (CAC-A) Cut-ting and Gouging
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
File: Engine Drive
Visit our website at
www.MillerWelds.com
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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 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 DEFINITIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturers Rating Label 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 SPECIFICATIONS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, And Operating Angles 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Volt-Ampere Curves 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Fuel Consumption 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Duty Cycle And Overheating 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. AC Generator Power Curve 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4INSTALLATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Mounting Welding Generator 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Installing Exhaust Pipe 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Activating The Dry Charge Battery (If Applicable) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting The Battery 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Engine Prestart Checks 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Connecting To Weld Output Terminals 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting Weld Cable Sizes* 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Connecting To Remote 14 Receptacle RC14 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 OPERATING CC/CV FLUX CORE WELDING GENERATOR 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls (See Section 5-2) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Description Of Front Panel Controls (See Section 5-1) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Process/Contactor Switch 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. Lift-ArcStart Procedure 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Remote Voltage/Amperage Control 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 OPERATING CC/CV WELDING GENERATOR 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls (See Section 6-2) 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Description Of Front Panel Controls (See Section 6-1) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Process/Contactor Switch On CC/CV Models 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Lift-ArcStart Procedure 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Remote Voltage/Amperage Control 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 OPERATING AUXILIARY EQUIPMENT 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. CC Model Auxiliary Power Receptacles 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. CC/CV Model Auxiliary Power Receptacles 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 MAINTENANCE 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Caterpillar Customer Assistance 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Checking Generator Brushes 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Servicing Air Cleaner 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Inspecting And Cleaning Spark Arrestor Muffler 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Servicing Engine Cooling System 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Adjusting Engine Speed On Standard Models 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Adjusting Engine Speed On Models With Automatic Idle (Optional) 36. . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Servicing Fuel And Lubrication Systems 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
8-11. Overload Protection 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Optional Voltmeter/Ammeter Help Displays 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 THEORY OF OPERATION 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10
TROUBLESHOOTING 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Troubleshooting Tables 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Troubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) 46. . . . . . . . . . . . . . . .
10-3. Troubleshooting Values For Circuit Diagram (Use With Section 10-2) 48. . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Waveforms For Sections 10-2 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Filter Board PC6 Testing Information 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Filter Board PC6 Test Point Values 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-7. Module Testing Information 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-8. Main Control Board PC1 Testing Information 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-9. Main Control Board PC1 Test Point Values 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-10. Voltage Regulator Board PC3 Testing Information 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-11. Voltage Regulator Board PC3 Test Point Values 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-12. Meter Display Board PC2 Testing Information 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-13. Meter Display Board PC2 Test Point Values 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14. Idle Module PC5 Testing Information And Troubleshooting Flow Chart 58. . . . . . . . . . . . . . . . . . . . . . .
10-15. Replacing Brushes And Cleaning Slip Rings 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-16. Checking Unit Output After Servicing 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 DISASSEMBLY AND REASSEMBLY 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Disassembly Of Unit 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Disassembly Of Generator 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Other Torque Values 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4. Replacing Rectifier SCR Modules 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 ELECTRICAL DIAGRAMS 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 RUN-IN PROCEDURE 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Wetstacking 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Run-In Procedure Using Load Bank 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3. Run-In Procedure Using Resistance Grid 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 14 PARTS LIST EFFECTIVE WITH LE341957 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14-1. Main Assembly (CC/CV Model Shown) 82. . . . . . . . . . . . . . . . . . . . .
Figure 14-2. Panel, Front w/Components Prior To LF350569 87. . . . . . . . . . . . . . .
Figure 14-3. Panel, Front w/Components (CC Model) Effective W/LF350569 89
Figure 14-4. Panel, Front w/Components (CC/CV Model) Effective W/LF350569 . . . . .91
Figure 14-5. Control Panel 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14-6. Generator 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14-7. Rectifier Assembly For CC Models 95. . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14-8. Rectifier Assembly For CC/CV Models 96. . . . . . . . . . . . . . . . . . . . . .
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dec_rot_6/05
Declaration of Conformity forEuropean Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).NOTE
Manufacturer: European Contact:
Miller Electric Mg. Co. Mr. Danilo Fedolfi,1635 W. Spencer St. Managing 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
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Noise level of Welding Generators: 2000/14/EC
Standards
Arc Welding Equipment Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Rotating Electrical Machines Part 1: Rating and Performance.
IEC 60034-1 Ed. 10.2 1999-08
Rotating Electrical Machines Part 5: Classification Of Degrees Of Protection Provided By Enclosure Of RotatingElectrical Machines (IP Code) IEC 60034-5 2001-06
Insulation Coordination For Equipment Within Low-Voltage Systems:Part 1: Principles, Requirements and Tests: IEC 60664-1 Ed. 1.1 2000-04
Arc Welding Equipment Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10 August 2002
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
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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).NOTE
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, Italy
Phone: 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.
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TM-4435 Page 1Big Blue 400 CX
SECTION 1 SAFETY PRECAUTIONS FOR SERVICING Warning: Protect yourself and others from injury read and follow these precautions.
1-1. Symbol UsageOM-4435E - 200511, safety_rtm 3/06
Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.
Marks a special safety message.
Means Note; not safety related.
This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.
1-2. Servicing Hazards
The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid 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 before testing or repairing unit un-less the procedure specifically requires an en-ergized 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.
When testing live unit, use the one-hand method. Do not put bothhands inside unit. Keep one hand free.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters. Stop engine on inverter and discharge input capacitors according
to instructions in Troubleshooting Section before touching anyparts.
MOVING PARTS can cause injury.
Keep away from moving parts such as fans,belts, and rotors.
Have only qualified people remove doors,panels, covers, or guards for maintenanceand troubleshooting as necessary.
Keep hands, hair, loose clothing, and tools away from movingparts.
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.
ENGINE EXHAUST GASES can kill.
Do not breathe exhaust fumes.
Use in open, well-ventilated areas, or vent ex-haust outside and away from any building air in-takes.
FUEL can cause fire or explosion.
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.
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-4435 Page 2 Big Blue 400 CX
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.
If the engine is warm, checking is needed, andthere is no overflow tank, follow the next twostatements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before completely
removing cap.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away from servicingareas until consulting your doctor.
FALLING UNIT can cause injury.
Use lifting eye to lift unit and properly installedaccessories only. Do not exceed maximum lifteye weight rating (see Specifications).
Lift and support unit only with proper equip-ment andcorrect procedures.
Securely attach components to lifting equip-
ment. If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
HOT PARTS can cause severe burns.
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.
SHOCK HAZARD from testing.
Stop engine 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.
TILTING OR TIPPING can cause injury.
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.
H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio
navigation, 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.
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 themanufacturer.
Reinstall injectors and bleed air from fuel system according toengine manual.
1-3. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases whichcontain chemicals known to the State of California to causebirth defects and, in some cases, cancer. (California Health &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 reproductiveharm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects, andother 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.
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 fromoperator as practical.
5. Connect work clamp to workpiece as close to the weld aspossible.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going nearwelding operations. If cleared by your doctor, then following the aboveprocedures is recommended.
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SECTION 2 DEFINITIONS
2-1. 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 load
above 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.
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2-2. Manufacturers Rating Label
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2-3. Symbols And Definitions
Some symbols are found only on CE products.NOTE
Stop EngineFast (Run, Weld/
Power)Slow (Idle) Start Engine
Starting Aid
(Preheat)Battery (Engine)
Engine Oil
PressureEngine Oil
Check Injectors/Pump
Check ValveClearance
FuelProtective Earth
(Ground)
Positive NegativeCertified/Trained
MechanicWelding 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
hHours
sSeconds 1 Single Phase
3Three Phase
Read Operators
Manual
Circuit ProtectionDo Not Switch
While Welding
ElectrodeConnection
Work Connection 3G
Engine-Driven,Three-Phase
Alternator WithRectifier
Hz Hertz
X Duty Cycle U0Rated No Load
Voltage (Average) U2ConventionalLoad Voltage n
Rated LoadSpeed
n1 Rated IdleSpeed n0 Rated No LoadSpeed I Current I2Rated Welding
Current
Contactor On Arc Force (Dig) Lift-Arc TIGRemote FootControl TIG
(GTAW)
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SECTION 3 SPECIFICATIONS3-1. Weld, Power, And Engine Specifications
WeldingMode
Weld OutputRange
Rated WeldingOutput
MaximumOpen-Circuit
Voltage
Auxiliary Power Rating EngineFuel
Capacity
20
410 A
300 A, 32 Volts DC
GeneratorSingle-Phase,
CC/DC 60% Duty Cycle
250 A, 30 Volts DC100% Duty cycle
10 kVA/kW, 91/46 A,110/220 V AC,
60 Hz Caterpillar 3013CWaterCooled 11.5 gal
CV/DCFlux Core
14 40 V300 A, 29 Volts DC
60% Duty Cycle
250 A, 26.5 Volts DC100% Duty cycle
7Receptacles
110/55 V AC Receptacles5.5 kVA/kW, 50/100 A
220/110 V AC Receptacles11 kVA/kW, 50/20 A
ThreeCylinder21.7 HP Diesel Engine
.(43.5 L)
3-2. Dimensions, Weights, And Operating Angles
Dimensions
Height32 in (813 mm)
35-3/4 in (908 mm)
(to top of lift eye) G
Width
26-1/4 in (667 mm)(mtg. brackets turned in)
28-3/4 in (730 mm)(mtg. brackets turned out)
Do not exceed tilt angles or engine couldbe damaged or unit could tip.
Do not move or operate unit where it couldti .
Depth 56 in (1422 mm)
p.
A 56 in (1422 mm)
B 54 in (1372 mm) A
C 52 in in (1321 mm)B C
D 2 in (51 mm)
E 26 in (660 mm)
F 7/8 in (22 mm) 30
G 27-3/4 in (705 mm)
30
H9/16 in (14 mm) Dia.
4 Holes Front Panel End
H20
20
Weight
No fuel: 1100 lb (499 kg)
w/ fuel: 1199 lb (544 kg)
F
E
Lifting Eye Weight Rating:1500 lb (680 kg) Maximum
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DC AMPERES
0 100 200 300 400 500
0
20
40
60
80
100
DCVOLTS
3-3. Volt-Ampere Curves
222 108 / 221 800 / 217 518
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
DCVOLTS
DC AMPERES
0 100 200 300 400 500
100
80
60
40
20
0
MIN MAX300
MAX
MIN
DC AMPERES
DCVOLTS
0 100 200 300 400 5000
10
20
30
40
50
60
70
80
90
100
MIN 300
MAX
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3-4. Fuel Consumption
The curve shows typical fuel useunder weld or power loads.
217 509
IDLE
DC WELD AMPERES AT 100% DUTY CYCLE
U.S.GAL/HR.
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
0 50 100 150 200 250 300 350 400
Continuous Welding
3-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.
Exceeding duty cycle can
damage unit and voidwarranty.
100% Duty Cycle At 250 Amperes
217 515
10 15 20 25 30 40 50 60 80 100
CCCV
1000
800
600
500
400
300
250
200
150
100
WELD
AMPERES
% DUTY CYCLE
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3-6. AC Generator Power Curve
220 346B
The ac power curve shows the gen-erator power in amperes.
AC AMPERES IN 110V MODE
AC AMPERES IN 220V MODE
ACVO
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
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SECTION 4 INSTALLATION
install3 6/05 Ref. 800 652 / Ref. 800 477-A / 803 274
Always securely fasten weld-ing generator onto transportvehicle or trailer and complywith all DOT and other applica-ble codes.
Always ground generator
frame to vehicle frame to pre-vent electric shock and staticelectricity hazards.
If unit does not have GFCI re-ceptacles, use GFCI-protectedextension cord.
See Section3-2for lifting eyerating.
See Section4-2for mountinginformation.
Grounding:
1 Equipment Grounding Terminal(On Front Panel)
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipmentground terminal to metal vehicleframe. Use #10 AWG or larger insu-lated copper wire.
Electrically bond generator frame tovehicle frame by metal-to-metal contact.
GND/PE
1
2
3
18 in(460 mm)
18 in(460 mm)
18 in(460 mm)
18 in(460 mm)
18 in(460 mm)
Movement
Airflow Clearance
4-1. Installing Welding Generator
OR
Grounding
Bed liners, shipping skids, and some runninggears insulate the welding generator from thevehicle frame. Always connect a ground wirefrom the generator equipment grounding termi-nal to bare metal on the vehicle frame as shown.
OR
Location
OR
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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.
Do not mount unit by sup-porting the base only at thefour mounting brackets.Use cross-supports to ade-quately support unit and pre-
vent damage to base.Mounting Surface:
1 Cross-Supports
2 Mounting Brackets (Supplied)
Mount unit on flat surface or 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 6/05 803 274 / 200 864-A / Ref 804 444-A
Do not use flexible mounts.
1
OR
3
CC model shown.
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4-3. Installing Exhaust Pipe
1/2 in
Tools Needed:
803 582F / Ref. 226 386
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.
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TM-4435 Page 13Big Blue 400 CX
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 Caps
6 Sulfuric Acid Electrolyte(1.265 Specific Gravity)
7 Well
Fill each cell with electrolyte tobottomof 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 cables
and install battery.
When electrolyte is low, addonly 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:
Ref. 804 009-C / Ref. 226 386 / S-0756-C
Close door after connecting battery.
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TM-4435 Page 14 Big Blue 400 CX
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 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 before
the engine shuts down. Check oil leveloften 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 13.
Fuel
Do not use gasoline. Gasoline willdamage 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 34F (37C). Add anti-
freeze to mixture if using the unit in tempera-
tures below 34F (37C).
Keep radiator and air intake clean and freeof dirt.
Incorrect engine temperature candamage engine. Do not run enginewithout a properly working thermo-stat and radiator cap.
To improve cold weather starting:
Use Preheat switch (see Section5-1).
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 Section8-1).
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
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TM-4435 Page 15Big Blue 400 CX
4-7. Connecting To Weld Output Terminals
Tools Needed:
3/4 in
Ref.804 009-C / Ref. 226 386 / 803 778-A
6
4
5
Do not 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 Terminal4 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 Welding
For 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 5-3).
MIG and FCAW Welding
For 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 5-3).
For Direct Current Electrode Negative(DCEN), reverse cable connections.
12
CC/CV model shown.
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TM-4435 Page 16 Big Blue 400 CX
4-8. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding***
100 ft (30 m) or Less150 ft(45 m)
200 ft(60 m)
250 ft(70 m)
300 ft(90 m)
350 ft(105 m)
400 ft(120 m)
Weld OutputTerminals
Stop engine beforeconnecting to weld out-
put terminals.
Do not use worn, dam-aged, undersized, orpoorly spliced cables.
Welding
Amperes
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.( ) = mm2for 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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TM-4435 Page 17Big Blue 400 CX
4-9. Connecting To Remote 14 Receptacle RC14
CC/CV model shown. Socket* Socket Information
24 VOLTS AC
A 24 volts ac. Protected by sup-plementary protector CB8.
B Contact closure to A completes24 volt ac contactor control
circuit.
C Output to remote control:+10volts dc in MIG mode; 0 to +10volts dc in Stick or TIG mode.
REMOTEOUTPUT
D Remote control circuit common.
CONTROL 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.
OR H Voltage feedback: 1 volt per 10arc volts.
GND K Chassis common.
Ref 804 009-C
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.
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TM-4435 Page 18 Big Blue 400 CX
SECTION 5 OPERATING CC/CV FLUX CORE WELDING GENERATOR
5-1. Front Panel Controls (See Section 5-2)
226 390A / 804 009C
1 2 546 7 89 10
3
Stop
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TM-4435 Page 19Big Blue 400 CX
5-2. Description Of Front Panel Controls (See Section 5-1)
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), and stopengine.
In Run position, engine runs at weld/powerspeed. In Auto position (optional), engineruns at idle speed at no load and weld speedwith load applied.
3 Engine Stop Lever
Use lever to stop engine if Engine Controlswitch does not work.
The Engine Stop lever shuts off the fuelsupply. However, the Engine Stop leverwill not stop the engine if the engine candraw fuel-rich air from the surrounding
atmosphere (oil refineries).
To Start:
Do not use ether.
If engine does not start, let engine cometo a complete stop before attempting re-
start.
Above 32 F (0 C): turn Engine Controlswitch to Start. Release Engine Control
switch when engine starts.
Below 32F (0C):turn engine control switchto Auto position. Push Preheat switch up for60 seconds. Turn Engine Control switch toStart. Release Engine Control switch andPreheat switch when engine starts.
To Stop: turn Engine Control switch to Offposition.
Engine Gauges, Meters, And Lights
4 Fuel Gauge/Hourmeter
Use gauge to check fuel level or total engineoperating hours.
To check fuel level or engine hours when en-gine is not running, turn Engine Control switchto Run or Auto (optional) position.
5 Engine Indicator Light
Light goes on and engine stops if engine tem-perature exceeds 230 F (110 C) or engineoil pressure is below 10 psi (69 kPa).
Normal engine temperature is 180 - 203 F (82 - 95 C). Normal oil pressure is 30- 60 psi (207 - 414 kPa).
Do not run engine until trouble isfixed.
Weld Controls
6 Remote Control Receptacle
Use receptacle to connect remote controlsand wire feeders.
When a remote control is connected to theRemote receptacle, the Auto Sense Remotefeature automatically switches voltage/am-perage control to the remote control (see Sec-tion 4-9).
If no remote control is connected to the Re-mote receptacle, the front panel Voltage/Am-
perage control adjusts voltage and amper-age.
If a remote device connected to RemoteReceptacle RC14 is faulty or is discon-
nected, the meters display Help 25 (seeSection 8-12). Clear fault by stopping
and restarting the unit or by turning Pro-cess/Contactor switch to another posi-tion.
7 Process/Contactor Switch
See Section 5-3 for Process/Contactorswitch information.
8 Voltage/Amperage Control
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage.With Process/Contactor switch in any Wire(MIG) position, use control to adjust voltage.
With Process/Contactor in any Stick or TIGmode and a remote control connected to theremote control receptacle, high output limit isset by the front panel Voltage/Amperage con-trol. The remote control adjusts output be-tween minimum and the high limit set by thefront panel control.
With Process/Contactor switch in any MIGmode and a remote control connected to theremote control receptacle, the front panelVoltage/Amperage control has no effect onweld output.
Weld Meters (Optional)
Weld meters also work in combination todisplay troubleshooting help codes (seeSection8-12).
9 DC Voltmeter
Voltmeter displays preset voltage (MIG weld-ing) with contactor off, and actual output volt-age with the contactor on. Voltmeter displaysvoltage at the weld output terminals, but notnecessarily the welding arc due to resistanceof cable and connections.
To set voltage, turn contactor off and turn Pro-cess/Contactor switch to Wire position. TurnV/A control until desired voltage is displayedon Voltmeter. When welding is finished, volt-meter displays weld voltage and then defaultsto preset voltage.
10 DC AmmeterAmmeter displays preset amperage (Stickand TIG only) when not welding, and actualoutput amperage when welding.
To set amperage, turn Process/Contactorswitch to Stick or TIG position. Turn V/A con-trol until desired amperage is displayed onAmmeter. When welding is finished, ammeterdisplays weld amperage and then defaults topreset amperage.
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5-3. Process/Contactor Switch
1 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 the Lift-Arc TIG mode for TIG(GTAW) welding using the Lift-Arc TIGstarting procedure (see Section 5-4).
1
Ref 804 444A / Ref 226 390A
Process/Contactor Switch Settings
Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)
Remote On/Off Switch Required
TIG HF Required Or Scratch
Start
GTAW With HF Unit, Pulsing Device,Or Remote Control At Remote 14 Receptacle Active
Remote On/Off SwitchRequired CV FeederUsing 24 Volt Remote
Flux Corew/Constant Speed Feeder
At Remote 14 Receptacle Active
Weld Terminals Always On WireFlux Core
w/Voltage Sensing FeederElectrode Hot Active
Weld Terminals Always On StickStick (SMAW),
Air Carbon Arc (CAC-A) Cutting AndGouging
Electrode Hot Active
Weld Terminals Always On TIGLift-Arc
TIG Lift-Arc (GTAW) Electrode Hot Active
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5-4. Lift-ArcStart Procedure
Lift-Arc TIG
With Lift-ArcTIG 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 DCEN
GTAW process when HF Startmethod is not permitted, or toreplace the scratch method.
1
1 2SecondsTouch
Do NOT Strike Like A Match!
2
Lift-Arc Start Method
Notes
Work like a Pro!Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
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5-5. Remote Voltage/Amperage Control
1 Remote 14 Receptacle RC14
Connect 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 volt-age/amperage control to the remote con-trol. When a device is connected to the Re-
mote receptacle, remote voltage/amper-
age control is always available regardlessof the position of the Process/Contactor
switch.
0774 / Ref.226 390A / Ref 804 444A
Example: Remote Voltage Control (MIG)
Adjust Optional Remote ControlTo Desired Weld Output
Set Remote Process
Example: Combination Remote Amperage Control (TIG)
Adjust Optional Remote ControlSet V/A Control
To Limit Max. Output:About 205 A
In Example:Process =Remote TIG
Min = 20 A DCMax = About 205 A DC
Max (205 A DC)
Min (20 A DC)
Connect RemoteControl To RemoteReceptacle RC14
Connect RemoteControl To RemoteReceptacle RC14
Set Remote Process(Only If Remote On/Off
Control Is Desired)
1
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Notes
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SECTION 6 OPERATING CC/CV WELDING GENERATOR
6-1. Front Panel Controls (See Section 6-2)
226 386-B / 804 009-C
1 2 546 78 9 10
3
Stop
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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), and stopengine.
In Run position, engine runs at weld/powerspeed. In Auto position (optional), engineruns at idle speed at no load and weld speedwith load applied.
3 Engine Stop Lever
Use lever to stop engine if Engine Control
switch does not work.
The Engine Stop lever shuts off the fuelsupply. However, the Engine Stop leverwill not stop the engine if the engine candraw fuel-rich air from the surrounding
atmosphere (oil refineries).
To Start:
Do not use ether.
If engine does not start, let engine cometo a complete stop before attempting re-
start.
Above 32 F (0 C): turn Engine Controlswitch to Start. Release Engine Controlswitch when engine starts.
Below 32F (0C):turn engine control switchto Auto position. Push Preheat switch up for60 seconds. Turn Engine Control switch toStart. Release Engine Control switch andPreheat switch when engine starts.
To Stop: turn Engine Control switch to Offposition.
Engine Gauges, Meters, And Lights
4 Fuel Gauge/Hourmeter
Use gauge to check fuel level or total engine
operating hours.
To check fuel level or engine hours when en-gine is not running, turn Engine Control switchto Run or Auto (optional) position.
5 Engine Indicator Light
Light goes on and engine stops if engine tem-perature exceeds 230 F (110 C) or engineoil pressure is below 10 psi (69 kPa).
Normal engine temperature is 180 - 203 F (82 - 95 C). Normal oil pressure is 30- 60 psi (207 - 414 kPa).
Do not run engine until trouble isfixed.
Weld Controls
6 Remote Control Receptacle
Use receptacle to connect remote controlsand wire feeders.
When a remote control is connected to theRemote receptacle, the Auto Sense Remotefeature automatically switches voltage/am-perage control to the remote control (see Sec-tion 4-9).
If no remote control is connected to the Re-mote receptacle, the front panel Voltage/Am-perage control adjusts voltage and amper-age.
If a remote device connected to RemoteReceptacle RC14 is faulty or is discon-
nected, the meters display Help 25 (seeSection 8-12). Clear fault by stopping
and restarting the unit or by turning Pro-cess/Contactor switch to another posi-tion.
7 Process/Contactor Switch
See Section 5-3 for Process/Contactorswitch information.
8 Voltage/Amperage Control
With Process/Contactor switch in any Stick orTIG setting, use control to adjust amperage.With Process/Contactor switch in any Wire(MIG) position, use control to adjust voltage.
With Process/Contactor in any Stick or TIGmode and a remote control connected to theremote control receptacle, high output limit isset by the front panel Voltage/Amperage con-trol. The remote control adjusts output be-tween minimum and the high limit set by thefront panel control.
With Process/Contactor switch in any MIGmode and a remote control connected to theremote control receptacle, the front panelVoltage/Amperage control has no effect onweld output.
Weld Meters Weld meters also work in combination to
display troubleshooting help codes (seeSection8-12).
9 DC Voltmeter
Voltmeter displays preset voltage (MIG weld-ing) with contactor off, and actual output volt-age with the contactor on. Voltmeter displaysvoltage at the weld output terminals, but notnecessarily the welding arc due to resistanceof cable and connections.
To set voltage, turn contactor off and turn Pro-cess/Contactor switch to Wire position. TurnV/A control until desired voltage is displayedon Voltmeter. When welding is finished, volt-
meter displays weld voltage and then defaultsto preset voltage.
10 DC Ammeter
Ammeter displays preset amperage (Stickand TIG only) when not welding, and actualoutput amperage when welding.
To set amperage, turn Process/Contactorswitch to Stick or TIG position. Turn V/A con-trol until desired amperage is displayed onAmmeter. When welding is finished, ammeterdisplays weld amperage and then defaults topreset amperage.
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6-3. Process/Contactor Switch On CC/CV Models
1 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
226 386-B / 804 009-C
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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6-5. Remote Voltage/Amperage Control
1 Remote 14 Receptacle RC14
Connect 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 volt-age/amperage control to the remote con-trol. When a device is connected to the Re-
mote receptacle, remote voltage/amper-
age control is always available regardlessof the position of the Process/Contactor
switch.
0774 / Ref.226 386-B / 804 009-C
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 RemoteControl to desired
weld output
Weld meters will alwaysshow the combined mainand remote control settingand machine welds atnominal output setting ofthe meter.
Weld meters show presetoutput when not welding.Set WIRE Process
Connect RemoteControl To RemoteReceptacle RC14
Adjust Optional RemoteControl to desired
weld output
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SECTION 7 OPERATING AUXILIARY EQUIPMENT
7-1. CC Model Auxiliary Power Receptacles
Ref. 217 359-A
1 220V 16 A AC Receptalce RC12
2 110V 20 A AC Receptacle GFCI1
If a ground fault is detected, GFCI Resetbutton pops out and receptacle does notwork. Check for faulty equipment plugged inreceptacle. Press button to reset GFCI re-ceptacle.
3 Supplementary Protector CB5
CB5 protects GFCI1 from overload. If asupplementary protector opens, the recep-
tacle does not work. Press button to reset.
4 Earth Leakage Circuit Breaker ELCB1
5 Earth Leakage Circuit Breaker ELCB2
ELCB1 protects RC12 and ELCB2 protectsRC11 from overload and earth leakagefault. If a circuit breaker opens, the recep-tacle does not work. Place switch in Onposition to reset circuit breaker.
6 220V 32A AC Receptacle RC11
Receptacles GFCI1, RC11, and RC12supply 60 Hz single-phase power at weld/power speed.
Maximum combined output of all recep-tacles is 10 kVa/kW.
At least once a month, run engine atweld/power speed and press test but-ton to verify ELCB1, ELCB2, and GFCI
are working properly.
Generator power decreases as weldoutput increases.
1 2 3 4 5 6
7-2. CC/CV Model Auxiliary Power Receptacles
226 386
1 110 V 16 A AC Receptacle RC12
2 Earth Leakage Circuit BreakerELCB1
3 Earth Leakage Circuit BreakerELCB2
ELCB1 protects RC12 and ELCB2 protectsRC11 from overload and earth leakage
fault. If a circuit breaker opens, the recep-tacle does not work. Place switch in Onposition to reset circuit breaker.
At least once a month, run engine atweld/power speed and press test but-ton to verify ELCB1 and ELCB2 areworking.
4 110 V 32 A AC Receptacle RC11
RC11 and RC12 supply 60 Hz single-phasepower at weld/power speed.
Generator power decreases as weldoutput increases.
Combined output of all receptacles is limit-ed to the 10 kVA/kw rating of the generator.
1 2 3 4
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SECTION 8 MAINTENANCE8-1. Maintenance Label
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8-2. Routine Maintenance
Stop engine before maintaining.
See Engine Manual and Maintenance Labelfor important start-up, service, and storage
information. Service engine more often ifused in severe conditions.
Recycle enginefluids.
= Check = Change = Clean = Replace* To be done by Factory Authorized Service Agent
Reference
Every8Hours
Section 4-6,8-10
Coolant Level Fuel Level Oil Level Oil, Fuel Spills
Every50Hours
Section 8-5
Air Cleaner Element Weld Terminals
Every100Hours
Battery Terminals Air Cleaner Hoses
Every250Hours
1/2 in.(13 mm)
EngineManual,Section 8-6,8-10
Unreadable Labels Fan Belt Tension Oil Oil Filter Spark Arrestor
Every500Hours
Weld Cables FuelFilter Inline Fuel Filter
Every1000Hours
OR
SLUDGE
FUELSection 4-6,8-4, 8-7,8-10, andEngineManual
Radiator Fluid Level Inside Unit Valve Clearance* Drain Sludge
Slip Rings* Brushes*
Every2000
Hours
Injectors*
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8-3. Caterpillar Customer Assistance
Service
When a problem arises concerning the op-eration or service of the engine, the prob-lem will normally be managed by the dealerin your area.
Your satisfaction is a primary concern toCaterpillar and to Caterpillar dealers. If youhave a problem that has not been handledto your complete satisfaction, follow thesesteps:
1 Discuss your problem with a managerfrom the dealership.
2 If your problem cannot be resolved atthe dealer level without additionalassistance, call a Field ServiceCoordinator at 1-800-447-4986.
3 If your needs still have not been met,submit the matter in writing to:
Caterpillar Inc.Manager, Customer Service,Engine DivisionMossville Bldg AP.O. Box 600Peoria, IL 61552-0600
Please follow the above steps in sequenceif a problem arises.
Website Address
www.caterpillar.com
Altitude
Contact the Caterpillar applications depart-ment for information on the effect of ambientconditions on Caterpillar 3024 engines.
8-4. Checking Generator Brushes
Ref 226 386-B / S0233A
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
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8-5. Servicing Air Cleaner
Stop engine.
Do not run engine without aircleaner or with dirty element. En-gine damage caused by using adamaged element is not coveredby the warranty.
The air cleaner primary element canbe cleaned but the dirt holding capac-
ity 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 damagemakes cleaning a risk. Consider therisk of unwarrantable equipmentdamage when determining whetherto clean or replace the primary ele-
ment.
If you decide to clean the primary ele-ment, we strongly recommend instal-ling an optional safety element to pro-vide additional engine protection.
Never clean a safety element. Re-place the safety element after servic-ing the primary element three times.
Clean or replace primary element if dirty(see note above before cleaning). Re-placeprimary 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 housingwith damp cloth. Reinstall safety element(if present). Reinstall cap.
Do not clean housing with airhose.
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 nozzle2 in (51 mm)from element.
2
aircleaner1 2/01ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 226 386-B
Optional
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8-6. Inspecting And Cleaning Spark Arrestor Muffler
803 582-F / Ref. 226 386-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 to
blow out cleanout hole. If nothingblows out of hole, briefly cover endof exhaust pipe with fireproofmaterial.
Stop engine and let cool.
Reinstall cleanout plug.
Tools Needed:
3/8 in
1
2
3
8-7. Servicing Engine Cooling System
804 009C / Ref 226 386-B
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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8-8. Adjusting Engine Speed On Standard Models
804 009C
3
1
2
RPM (Hz)Engine Speed
(No Load)
Weld/Power1850 (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 Nut
2 Adjustment Screw
Loosen nut. Turn screw until engineruns at weld/power speed. Tightennut.
Do not set engine speed higherthan specified. Tampering with
adjustments other than shownmay affect engine warranty.
3 Engine Stop Lever
Stop engine.Close door.
Tools Needed:
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8-9. Adjusting Engine Speed On Models With Automatic Idle (Optional)
804 492-A / Ref. 803 563-E
1880 rpm max(62.6 Hz)
1250 rpm(41.6 Hz)
Engine Speed(No Load)
After tuning engine, check engine speedwith tachometer or frequency meter. Seetable for proper no load speed. If neces-sary, adjust speed as follows:
Start engine and run until warm.
Turn Process/Contactor switch to Stick Weld Terminals Always On position.
Idle Speed Adjustment
1 Throttle Rod/Plunger
2 Locknut
Loosen locknut. Place Engine Controlswitch in Auto position.
Turn throttle rod and plunger until engineruns at idle speed. Tighten locknut.
Be sure solenoid plunger pulls all theway in (bottoms) when energized.
If necessary, move linkage to otherhole in bracket or move cotter pin toother hole in throttle arm to set idle
speed correctly.
Weld/Power Speed Adjustment
Weld/power speed adjustment mustbe done by the engine manufactur-ers factory authorized service
agent.Tampering with adjustments otherthan shown may affect engine war-
ranty.
Stop engine.
21
Tools Needed:
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8-10. Servicing Fuel And Lubrication Systems
Ref 226 386-B / 804 009C
Stop engine and let cool.
1 Oil Filter
2 Oil Drain Valve And Hose
3 Oil Fill Cap
4 Primary (Canister) Fuel Filter
5 Secondary (In-Line) FuelFilter
6 Fuel Tank Sludge Drain ValveTo 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 ifcracked 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. Remove
hose.
Close door.
After servicing, start engineand check for fuel leaks.Stop engine, tighten connec-tions as necessary, and wipeup spilled fuel.
Tools Needed:
3
5
2
4
1
6
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8-11. Overload Protection
Ref. 226 386-B / 803 566-E / 804 009-C
5
3
41
Stop engine.
1 Fuse F1
F1 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 (NotShown)
3 Supplementary Protector CB2
4 Supplementary Protector CB3
5 Supplementary Protector CB8
CB1 protects the engine battery cir-cuit. If CB1 opens, the engine will notcrank. CB1 automatically resetswhen the fault is corrected. If CB1
continues to open, check fuel sole-noid FS1, the fuel pump, throttle so-lenoid TS1, integrated rectifier SR1,engine alternator, glow plug, and cir-cuit boards PC2, PC3, and PC5.
CB2 protects the engine wiring har-ness. If CB2 opens, the engine willnot crank. Press button to reset IfCB2 continues to open, check fuelsolenoid FS1, the fuel pump, throttlesolenoid TS1, integrated rectifierSR1, and circuit board PC5 and FuelGauge/Hour Meter.
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.
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.
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8-12. Optional Voltmeter/Ammeter Help Displays
2
1
HL.P 22
HL.P 23
HL.P 24
HL.P 25
HL.P 20
HL.P 21
6
5
4
3
Ref. 804 009-C
Use the Voltmeter/Ammeter 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 Display
Indicates 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 Display
Indicates 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 Display
Indicates one of the rectifier outputSCRs has failed. If this display isshown, check the rectifier SCRs.
5 Help 24 Display
Verify engine speed is correct bychecking frequency at 115 volt acduplex receptacle (should beapproximately 62 Hertz with Engine
Control 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 Display
Indicates 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.
When a help code is displayednormally weld output hasstopped but generator power out-put may be okay. Auxiliary powermust 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 out-put and auxiliary power are notavailable, see Section 10-7 formodule testing information.
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SECTION 9 THEORY OF OPERATION
1 Engine
Supplies force to turn revolving fields.
2 Revolving Fields (Rotor)
Turn at 1885 rpm maximum for weld andpower. The speed and excitation currentof the field coils determine voltages instator windings.
3 Stator Windings
Supply power to exciter, generator pow-er, and weld circuits.
4 Fuse F1
Protects exciter windings from over-load.
5 Voltage Regulator Board PC3
Changes ac output of stator windings todc to supply excitation current to the ex-citer revolving field.
Controls field current in response tochanges in output load.
If PC3 senses an overload condition(shorted rotor), it protects itself by stop-
ping excitation current (weld and gener-ator power output stops).
6 Circuit Breakers CB4, CB5, andCB6
Protect AC receptacles from overload.
7 AC Receptacles GFCI1, GFCI2and RC11
Provide connection points and power forauxiliary equipment.
8 Circuit Breakers CB7 and CB8
Provide overload protection for 24 and115 volts ac portion of Remote 14 recep-tacle RC14.
9 Filter Board PC6/Remote Recep-
tacle RC14PC6 protects unit from high frequency,and RC14 connects remote amperage/voltage and contactor controls to unit.
When a remote control is connected tothe Remote receptacle, the Auto SenseRemote feature automatically switchesvoltage/amperagecontrol to the remotecontrol.
10 Voltage/Amperage Control R2
Adjusts weld output amperage or volt-age level.
11 Process/Contactor Switch R1
Selects weld process and weld outputon/off control.
Circuit
8
8
Breaker
CB7
9
ControlBoardPC1
115 VAC
24 VAC
+10 VDC OutputCommand Voltage
12
3Exciter
Stator Windings
Generator PowerWeld
RevolvingFields(Rotor)
Engine
VoltageRegulatorBoard PC3
5
21 3
CurrentFeedback
CircuitBreakers
6
CB4, CB5, CB6
7
4
Fuse F1
ACReceptacles
GFCI1, GFCI2,RC11
CircuitBreaker
CB8Filter BoardPC6/RemoteReceptacle
RC14
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12 Control Board PC1
Controls 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 TH1
Thermostat opens and stops allweld output if unit overheats.
14 Meter Board PC2
Displays preset and actual (rectifiedand filtered) values of the weld volt-age and amperage.
15 Main Rectifier
Changes ac weld current to dc.
Works with PC1 (item 12) to con-trols weld output by changing recti-fier SCR gate pulses (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 HD1
Provides current feedback signal toPC1.
18 Stabilizer Z1
Smooths (filters) weld outputcurrent.
19 Capacitor Bank C10
Filters the dc output voltage of mainrectifier.
20 Work (), CC, And CV WeldOutput Terminals
Provide weld output and allowmanual changing of output polarity.
AC Or DC Control Circuits
Weld Current Circuit
External Circuits
Thermostat
13
TH1
SCRGatingSignals
17
Hall 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
CV
BurdenResistor R3
CC/CV Model Shown. CC only model doesnot have capacitor bank C10 or CV weld out-put terminal.
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SECTION 10 TROUBLESHOOTING
10-1. Troubleshooting Tables
See Section 10-2for test points andvalues and Section 14and followingfor parts location.
Use MILLER Testing Booklet (PartNo. 150 853) when servicing this
unit.
Also see Voltmeter/Ammeter help displays to assist in troubleshooting weld problems (seeSection8-12).
Note
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 CB8 (see Section 8-11). Check for faulty remote device connected to
RC14.
Check and secure connections to Remote Control receptacle RC14 (see Section 4-9).
Check resistance and connections of Voltage/Amperage Adjust control R2; R2 is 1000 ohms 10%.Replace R2 if necessary.
Check reactor Z1 for signs of winding failure. Check continuity across windings, and check for properconnections. Replace Z1 if necessary.
Check Voltmeter/Ammeter help displays (see Section 8-12).
No weld output, or generator power out-put at ac receptacles.
Disconnect equipment from generator power receptacles during start-up.
Reset supplementary protector CB3 (see Section 8-11).
Check fuse F1, and replace if open (see Section 8-11). If F1 is open, check the voltage regulator boardPC3. If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Checkrotor and brushes before replacing PC3.
Check Voltmeter/Ammeter help displays (see Section 8-12).
Clean slip rings, and install new brushes if necessary (see Section 10-15).
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if nec-essary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator ifnecessary.
Determine if main control board PC1 or voltage regulator board PC3 is causing the lack of output (see
Section 10-7).
Check voltage regulator board PC3 and connections, and replace PC3 if necessary (see Section10-10).If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check rotorand brushes before replacing PC3.
Check main control board PC1 and connections, and replace PC1 if necessary (see Sections 10-8and
10-9).
Erratic weld output. Check and tighten connections inside and outside unit. Be sure connection to work piece is clean andtight.
Be sure weld cables have no nicks or gouges and no kinks.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
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Trouble Remedy
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor ifnecessary.
High weld output. Repair or replace remote control device.
Check hall device HD1, and replace if necessary (see Section 10-2).
Check main control board PC1 and connections, and replace PC1 if necessary (see Sections 10-8and
10-9).
Low weld output. Check engine speed, and adjust if necessary (see Section 8-8or 8-9).
Increase Voltage/Amperage Adjust control R2 setting.
Check fuse F1, and replace if open (see Section 8-11).
Repair or replace remote control device.
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if nec-essary.
Low open-circuit voltage. Check engine speed, and adjust if necessary (see Section 8-8or 8-9).
Check main control board PC1 and connections, and replace PC1 if necessary (see Sections 10-8and10-9)..
Check voltage regulator board PC3 and connections, and replace PC3 if necessary (see Section10-10).If PC3 senses an overload condition (shorted rotor), it protects itself by stopping weld output. Check rotorand brushes before replacing PC3.
Check SCRs in main rectifier, and replace if necessary (see Section 11-4). If any SCRs are re-placed, check capacitors C1 through C9 for a short or open, and check for proper connections. Re-place C1 through C9 if necessary.
No remote fine amperage control. Repair or replace remote control device.
Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 4-9).
No 24 volt ac output at Remote recep-tacle RC14.
Reset circuit breaker CB8 (24 volt) (see Section 8-11).
Check filter board PC6, and replace if necessary.
B. Generator Power
Trouble Remedy
No generator power output at ac recep-tacles; weld output okay.
Reset receptacle supplementary protectors (see Section 7-1).
Check resistance of generator power windings between leads 84 and 99. Replace stator if necessary.
No generator power or weld output. Disconnect equipment from generator power receptacles during start-up.
Check fuse F1, and replace if open (see Section 8-11). If F1 is open, check the voltage regulator boardPC3 (see Section 10-10). If PC3 senses an overload condition (shorted rotor), it protects itself by stop-ping weld output. Check rotor and brushes before replacing PC3.
Reset circuit breaker CB3 (see Section 8-11).
Check Voltmeter/Ammeter help displays (see Section 8-12).
Clean slip rings, and install new brushes if necessary (see Section 10-15).
Disconnect leads 105 and 108 from the rotor, and check continuity across slip rings. Replace rotor if nec-essary.
Disconnect stator excitation leads 100 and 101, and check continuity between leads. Replace stator ifnecessary.
Determine if main control board PC1 or voltage regulator board PC3 is ca