motosoldadoras miller

8/11/2019 Motosoldadoras Miller

1/106

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.


9/106


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.


10/106


2-2. Manufacturers Rating Label


11/106


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)


12/106


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


13/106


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


14/106


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


15/106


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


16/106


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


17/106


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.


18/106


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


safely. Read the

safety rules at

the beginning

of this manual.


19/106


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.


20/106


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


21/106


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.


22/106


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


23/106


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.


24/106


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


25/106


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.


26/106


5-3. 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


27/106


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


safely. Read the

safety rules at

the beginning

of this manual.


28/106


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


Set Remote Process(Only If Remote On/Off

Control Is Desired)

1


29/106


Notes


30/106


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


31/106


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.


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.


32/106


6-3. Process/Contactor Switch On CC/CV Models


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


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


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


33/106


34/106


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)


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


Adjust Optional RemoteControl to desired

weld output


35/106


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


36/106


SECTION 8 MAINTENANCE8-1. Maintenance Label


37/106


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*


38/106


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


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


39/106


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


40/106


8-6. Inspecting And Cleaning Spark Arrestor Muffler

803 582-F / Ref. 226 386-B


1 Spark Arrestor Muffler

2 Cleanout Plug

Remove plug and remove any 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.


Reinstall cleanout plug.

Tools Needed:

3/8 in

1

2

3

8-7. Servicing Engine Cooling System

804 009C / Ref 226 386-B


1 Radiator 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


41/106


8-8. Adjusting Engine Speed On Standard Models

804 009C

3

1

2

RPM (Hz)Engine Speed

(No Load)

Weld/Power1850 (61.7)

Maximum


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:


42/106


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:


43/106


8-10. Servicing Fuel And Lubrication Systems

Ref 226 386-B / 804 009C


1 Oil Filter

2 Oil Drain Valve And Hose

3 Oil Fill Cap

4 Primary (Canister) Fuel Filter

5 Secondary (In-Line) 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


44/106


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)




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.


45/106


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.


46/106


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


47/106


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.


48/106

TM-4435 Page 42 Big Blue 400CX

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.


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.


49/106

TM-4435 Page 43Big Blue 400CX

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.


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).


Clean slip rings, and install new brushes if necessary (see Section 10-15).


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

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